DP 4000e Series BSM

PROFESSIONAL DIGITAL TWO-WAY RADIO SYSTEM
MOTOTRBO™ PORTABLE
DP4800e
DP4801e
DP4601e
DP4600e
DP4400e
DP4401e
BASIC
SERVICE MANUAL
TM
iii
Foreword
This manual covers all models of the DP Series Portable Radios, unless otherwise specified. It includes all the information
necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance
procedures. This level of service goes down to the board replacement level and is typical of some local service centers,
self-maintained customers, and distributors.
Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions
! for safe usage contained in the Product Safety and RF
Caution Exposure booklet enclosed with your radio.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site:
http://www.motorolasolutions.com
For a list of Motorola TIA 4950 approved radio models, antennas, batteries, and other accessories,
please refer to UL Safety manual MN001111A01 enclosed with your radio.
TIA 4950
The radio models listed in UL Safety Manual MN001111A01, when properly equip with the battery PMNN4489_, is certified
for use per the classification below:
• Classification Rating Division 1, Class I, Groups C, D; Class II Group E, F, G; Class III. T3C.
Tamb = -25°C to +60 °C.
• Classification Rating Division 2, Class I, Groups A, B, C, D.
Repairs of Motorola TIA 4950 certified intrinsically safe radios must

must be carried out ONLY by Motorola I.S. trained personnel, who are
aware of the special parts required and the procedures necessary to
maintain the TIA 4950 conformance of the product. The Motorola
internal service centres undergo regular training and receive a
Motorola internal certification that enables them to conduct TIA 4950
repairs.
Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective
owners.
© 2016 Motorola Solutions, Inc.
All rights reserved.
v
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
MN002181A01-AA Initial Release Jan. 2016

vi
Notes
Table of Contents vii
Table of Contents
Foreword ........................................................................................................iii
Product Safety and RF Exposure Compliance ........................................................................................... iii
TIA 4950 ..................................................................................................................................................... iii
Computer Software Copyrights .................................................................................................................. iii
Document Copyrights ................................................................................................................................. iii
Disclaimer...................................................................................................................................................iv
Trademarks ................................................................................................................................................iv
Document History ......................................................................................... v
Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.2.1 Full Keypad Model........................................................................................................... 1-2
1.2.2 Limited Keypad Model ..................................................................................................... 1-3
1.2.3 Non Keypad Model .......................................................................................................... 1-4
1.3 .Portable Radio Model Numbering Scheme ................................................................................ 1-5
1.4 Model Charts ............................................................................................................................... 1-6
1.4.1 VHF Model Chart............................................................................................................. 1-6
1.4.2 UHF Model Chart............................................................................................................. 1-8
1.4.3 300 MHz Band Model Chart ............................................................................................ 1-9
1.4.4 350 MHz Band Model Chart .......................................................................................... 1-10
1.5 Specifications............................................................................................................................. 1-11
Chapter 2 Test Equipment and Service Aids ..................................... 2-1

2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids ................................................................................................................................. 2-2
2.3 Programming, Testing and Alignment Cable ............................................................................... 2-3
Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
3.3 Display Model Test Mode ............................................................................................................ 3-4
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-4
3.3.2 LCD Flicker Test Mode.................................................................................................... 3-4
3.3.3 LCD Display Test Mode................................................................................................... 3-4
3.3.4 RF Test Mode.................................................................................................................. 3-5
3.3.5 LED Test Mode.............................................................................................................. 3-10
3.3.6 Accelerometer Test ....................................................................................................... 3-10
3.3.7 Backlight Test Mode ...................................................................................................... 3-10
3.3.8 Speaker Tone Test Mode .............................................................................................. 3-10
3.3.9 Earpiece Tone Test Mode ............................................................................................. 3-10
viii Table of Contents
3.3.10 Audio Loopback Earpiece Test Mode............................................................................ 3-10

3.3.11 Battery Check Test Mode .............................................................................................. 3-11
3.3.12 Button/Knob/PTT Test Mode ......................................................................................... 3-11
3.4 Non-Display Model Test Mode................................................................................................... 3-13
3.4.1 Entering Non-Display Radio Test Mode ........................................................................ 3-13
3.4.2 RF Test Mode ................................................................................................................ 3-13
3.4.3 LED Test Mode.............................................................................................................. 3-13
3.4.4 Speaker Tone Test Mode .............................................................................................. 3-13
3.4.5 Earpiece Tone Test Mode ............................................................................................. 3-14
3.4.6 Audio Loopback Earpiece Test Mode............................................................................ 3-14
3.4.7 Battery Check Test Mode .............................................................................................. 3-14
3.4.8 Button/Knob/PTT Test Mode ......................................................................................... 3-14
Chapter 4 Radio Programming and Tuning ....................................... 4-1

4.1 Introduction .................................................................................................................................. 4-1
4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 AirTracer Application Tool............................................................................................................ 4-2
4.4 Radio Tuning Setup ..................................................................................................................... 4-2
4.5 RF Adaptor Assembly .................................................................................................................. 4-3
Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1

5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
5.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
5.4 Repair Procedures and Techniques – General............................................................................ 5-4
5.5 Disassembling and Reassembling the Radio — General ............................................................ 5-5
5.6 Radio Disassembly – Detailed ..................................................................................................... 5-6
5.6.1 Front Cover from Chassis Disassembly .......................................................................... 5-6
5.6.2 Chassis Disassembly..................................................................................................... 5-10
5.6.3 Interface Board, Keypad Board and LCD Disassembly................................................. 5-14
5.6.4 Speaker and Universal Connector Flex Disassembly.................................................... 5-17
5.6.5 Emergency Button Assembly Dissassembly ................................................................. 5-19
5.6.6 Bluetooth GPS Antenna Disassembly ........................................................................... 5-20
5.7 Radio Reassembly - Detailed .................................................................................................... 5-21
5.7.1 Bluetooth GPS Antenna and Emergency Button Reassembly ...................................... 5-21
5.7.2 Speaker and Universal Connector Flex Reassembly .................................................... 5-22
5.7.3 Interface Board, Keypad Board and LCD Reassembly ................................................. 5-24
5.7.4 Chassis Reassembly ..................................................................................................... 5-26
5.7.5 Chassis and Front Cover Reassembly .......................................................................... 5-29
5.8 Ensuring Radio Immersibility ..................................................................................................... 5-30
5.8.1 Servicing ........................................................................................................................ 5-30
5.8.2 Accidental Immersion .................................................................................................... 5-30
5.8.3 Specialized Test Equipment .......................................................................................... 5-30
5.8.4 Vacuum Pump Kit NLN9839.......................................................................................... 5-30
5.8.5 Pressure Pump Kit NTN4265 ........................................................................................ 5-31
5.8.6 Miscellaneous Hardware ............................................................................................... 5-31
5.8.7 Vacuum Test.................................................................................................................. 5-31
5.8.8 Pressure Test ................................................................................................................ 5-32
Table of Contents ix
5.8.9 Troubleshooting Leak Areas.......................................................................................... 5-33

5.8.9.1 Front Housing ................................................................................................. 5-33
5.8.9.2 Battery Contact Seal....................................................................................... 5-34
5.8.9.3 Air Ventilation Label........................................................................................ 5-35
5.8.9.4 Battery Maintenance....................................................................................... 5-35
5.8.10 Troubleshooting Charts ................................................................................................. 5-36
5.9 Radio Exploded Mechanical Views and Parts Lists ................................................................... 5-39
5.9.1 Full Keypad Model Exploded View and Parts List ......................................................... 5-39
5.9.2 Limited Keypad Model Exploded View and Parts List ................................................... 5-42
5.9.3 Non Keypad Model Exploded View and Parts List ........................................................ 5-45
5.9.4 Torque Chart ................................................................................................................. 5-51
Chapter 6 Basic Troubleshooting ....................................................... 6-1

6.1 Introduction .................................................................................................................................. 6-1
6.2 Replacement Back Cover Kit Procedures ................................................................................... 6-1
6.3 Power-Up Error Codes (Display Model only) ............................................................................... 6-2
6.4 Operational Error Codes .............................................................................................................. 6-4
Appendix A EMEA Regional Warranty, Service and Technical Support ..

A-1
A.1 Warranty and Service Support.....................................................................................................A-1
A.1.1 Warranty Period and Return Instructions ........................................................................A-1
A.1.2 After Warranty Period ......................................................................................................A-1
A.2 European Radio Support Centre (ERSC) ....................................................................................A-2
A.3 Piece Parts ..................................................................................................................................A-2
A.4 Technical Support ........................................................................................................................A-3
A.5 Further Assistance From Motorola ..............................................................................................A-3
Appendix B Limited Level 3 Servicing ...................................................B-1

B.1 Maintenance ................................................................................................................................B-1
B.2 Chip Components ........................................................................................................................B-1
B.3 Component and Parts list ............................................................................................................B-2
Glossary ......................................................................................... Glossary-1

x List of Figures
List of Figures
Figure 1-1. Full Keypad Model................................................................................................................ 1-2

Figure 1-2. Limited Keypad Model.......................................................................................................... 1-3
Figure 1-3. Non Keypad Model............................................................................................................... 1-4
Figure 1-4. Portable Radio Model Numbering Scheme .......................................................................... 1-5
Figure 2-1. Programming, Testing and Alignment Cable ........................................................................ 2-3
Figure 2-2. Pin Layout of Side Connector .............................................................................................. 2-4
Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup........................................................... 3-3
Figure 3-2. Battery Check Test Mode Display ...................................................................................... 3-11
Figure 4-1. CPS Programming Setup ..................................................................................................... 4-1
Figure 4-2. Radio Tuning Equipment Setup ........................................................................................... 4-2
Figure 4-3. RF Plug removal .................................................................................................................. 4-3
Figure 4-4. RF Adaptor holder ................................................................................................................ 4-3
Figure 4-5. RF Adaptor screw ................................................................................................................ 4-4
Figure 4-6. RF Adaptor complete assembly ........................................................................................... 4-4
Figure 5-1. Battery removal .................................................................................................................... 5-6
Figure 5-2. Antenna removal. ................................................................................................................. 5-6
Figure 5-3. Shroud removal .................................................................................................................... 5-7
Figure 5-4. Chassis removal................................................................................................................... 5-7
Figure 5-5. Chassis and Front Housing .................................................................................................. 5-8
Figure 5-6. Keypad flex removal............................................................................................................. 5-8
Figure 5-7. Interface flex removal ........................................................................................................... 5-9
Figure 5-8. GOB and mini GOB flex removal ....................................................................................... 5-10
Figure 5-9. Mainboard removal ............................................................................................................ 5-10
Figure 5-10. Top control seal removal .................................................................................................... 5-11
Figure 5-11. GOB removal ..................................................................................................................... 5-11
Figure 5-12. Battery contact seal removal .............................................................................................. 5-12
Figure 5-13. RF rubber plug removal ..................................................................................................... 5-12
Figure 5-14. Interface flex removal ......................................................................................................... 5-14
Figure 5-15. UC flex removal.................................................................................................................. 5-14
Figure 5-16. PTT flex removal ................................................................................................................ 5-15
Figure 5-17. Interface board removal ..................................................................................................... 5-15
Figure 5-18. Keypad board removal ....................................................................................................... 5-16
Figure 5-19. Display module removal ..................................................................................................... 5-16
Figure 5-20. UC escutcheon removal ..................................................................................................... 5-17
Figure 5-21. UC flex removal.................................................................................................................. 5-17
Figure 5-22. Speaker assembly removal ................................................................................................ 5-18
Figure 5-23. Speaker removal ................................................................................................................ 5-18
Figure 5-24. Emergency button removal ................................................................................................ 5-19
Figure 5-25. Bluetooth GPS antenna removal........................................................................................ 5-20
Figure 5-26. Bluetooth GPS antenna reassembly .................................................................................. 5-21
Figure 5-27. Emergency button reassembly........................................................................................... 5-21
Figure 5-28. Speaker retainer reassembly.............................................................................................. 5-22
Figure 5-29. Speaker reassembly........................................................................................................... 5-22
Figure 5-30. UC Escutcheon replacement ............................................................................................. 5-23
Figure 5-31. Display module reassembly ............................................................................................... 5-24
Figure 5-32. Keypad Board reassembly ................................................................................................. 5-24
Figure 5-33. Front housing reassembly .................................................................................................. 5-25
Figure 5-34. Chassis reassembly ........................................................................................................... 5-26
Figure 5-35. Thermal Pad....................................................................................................................... 5-26
Figure 5-36. Top control seal reassembly............................................................................................... 5-27
List of Figures xi
Figure 5-37. Main board and GOB reassembly...................................................................................... 5-28

Figure 5-38. Main board connectors. ..................................................................................................... 5-29
Figure 5-39. Chassis reassembly ........................................................................................................... 5-29
Figure 5-40. Connector Fitting - Fitting Seal Pump Connector............................................................... 5-30
Figure 5-41. Full Keypad Model Exploded View..................................................................................... 5-39
Figure 5-42. Limited Keypad Model Exploded View............................................................................... 5-42
Figure 5-43. Non Keypad Exploded View............................................................................................... 5-45
Figure B-1. PCB Top View ......................................................................................................................B-2
Figure B-2. PCB Bottom View.................................................................................................................B-2
xii Related Publications
List of Tables
Table 1-1. Radio Frequency Ranges and Power Levels ....................................................................... 1-1
Table 2-1. Recommended Test Equipment ........................................................................................... 2-1
Table 2-2. Service Aids ......................................................................................................................... 2-2
Table 2-3. Pin Configuration of Side Connector .................................................................................... 2-4
Table 3-1. Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2. Front Panel Access Test Mode Displays .............................................................................. 3-4
Table 3-3. Test Environments................................................................................................................ 3-5
Table 3-4. Test Frequencies .................................................................................................................. 3-5
Table 3-5. Test Frequencies .................................................................................................................. 3-6
Table 3-6. Transmitter Performance Checks......................................................................................... 3-7
Table 3-7. Receiver Performance Checks ............................................................................................ 3-9
Table 4-1. Software Installation Kits Radio Tuning Setup ..................................................................... 4-1
Table 5-1. Lead Free Solder Wire Part Number List ............................................................................. 5-4
Table 5-2. Lead Free Solder Paste Part Number List ........................................................................... 5-4
Table 5-3. Full Keypad Model Exploded View Parts List ..................................................................... 5-40
Table 5-4. Limited Keypad Model Exploded View Parts List ............................................................... 5-43
Table 5-5. Non Keypad Model Exploded View Parts List .................................................................... 5-46
Table 5-6. Additional Part List Table.................................................................................................... 5-48
Table 5-7. Torque Specifications for Screws ....................................................................................... 5-51
Table 6-1. Power-Up Error Codes ......................................................................................................... 6-2
Table 6-2. Operational Error Codes ...................................................................................................... 6-4
List of Tables xiii
Related Publications
IMPRES Adaptive Single-Unit Charger User Manual ..................................................................6816787H01
IMPRES Adaptive Multi-Unit Charger User Manual ....................................................................6816789H01
IMPRES Adaptive Multi-Unit Charger Service Manual ................................................................ 6871357L01
Remote Speaker Microphone User Manual................................................................................. 6871003L01
IMPRES Remote Speaker Microphone User Manual .................................................................. 6871004L01
UL Safety Manual ..................................................................................................................... MN001111A01
xiv Related Publications
Introduction: Notations Used in This Manual 1-1
Chapter 1 Introduction
1.1 Notations Used in This Manual

Throughout the text in this publication, you will notice the use of note and caution notations. These
notations are used to emphasize that safety hazards exist, and due care must be taken and
observed.
NOTE An operational procedure, practice, or condition that is essential to emphasize.
! CAUTION indicates a potentially hazardous situation which, if

not avoided, might result in equipment damage.
Caution
WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or injury.
1.2 Radio Description

The DP4000e series portable radios are available in the following frequency ranges and power
levels.
Table 1-1. Radio Frequency Ranges and Power Levels
Frequency Band Bandwidth Power Level
VHF 136–174 MHz 1 Watt or 5 Watt
UHF 403–527 MHz 1 Watt or 4 Watt
300 MHz Band 300–360 MHz 1 Watt or 4 Watt
350 MHz Band 350–400 MHz 1 Watt or 4 Watt
These digital radios are among the most sophisticated two-way radios available. They have a robust
design for radio users who need high performance, quality, and reliability in their daily
communications. This architecture provides the capability of supporting a multitude of legacy and
advanced features resulting in a more cost-effective two-way radio communications solution.
1-2 Introduction: Radio Description
1.2.1 Full Keypad Model
Antenna
Channel Selector Knob

On/Off Volume Control Knob
LED Indicator Emergency Button
Side Button 1
Universal
PTT Button Connector
Microphone Speaker
Side Button 2
LCD
Side Button 3
Menu Navigation Key
Front Buttons
Keypad
Figure 1-1. Full Keypad Model

• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counter-
clockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display):
- 132x90 highly transflective color display provides visual information about many radio
features.
• MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface.
• KEYPAD – Twelve keys that allows the user to input characters for various text based
operations. (For color display only)
• FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the
CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be
used with the radio. It has twelve points to which specific accessories will connect and be
activated.
• EMERGENCY BUTTON – Turns on and off the Emergency Operations.
Introduction: Radio Description 1-3
• SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like
keypad tones and voice audio).
1.2.2 Limited Keypad Model
Antenna

Side Button 1
Universal Connector
PTT Button
Microphone Speaker
Side Button 2 LCD

Side Button 3
Menu Navigation Key
Front Buttons
Figure 1-2. Limited Keypad Model

• LCD (Liquid Crystal Display):
- 132x90 highly transflective color display provides visual information about many radio
features.
• MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface.
• FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the
CPS.
used with the radio. It has twelve points to which specific accessories will connect and be
activated.
1-4 Introduction: Radio Description
keypad tones and voice audio).
1.2.3 Non Keypad Model
Antenna

Side Button 1
PTT Button Universal Connector

Microphone Speaker
Side Button 2
Side Button 3
Figure 1-3. Non Keypad Model

• SIDE BUTTONS – These 3 buttons are field programmable using the CPS.
used with the radio. It has twelve points to which specific accessories will connect to and be
activated.
keypad tones and voice audio)
Introduction: .Portable Radio Model Numbering Scheme 1-5
1.3 .Portable Radio Model Numbering Scheme
Model No.Example : MD H 5 6 J D N 9 R A 1 A N
Position : 1 2 3 4 5 6 7 8 9 10 11 12
AZ: Asia
LA: Latin America
AA: North America
MD: Europe Unique Variation
N: Standard Package
H: Portable
Version Letter
DP4000e Model Series: 56
Feature Level
1: Standard w/ UL
Band 2. Non-UL
J: 136-174 MHz
K: 300-360 MHz
N: 350-400 MHz
R: 403-527 MHz Primary System Type
A: Conventional
B: Trunking
Power Level C: Analog Only
C: 1.0,2.0,2.5 or 3.5 Watt
D: 3.5, 4.0 or 5.0 Watt
Primary Operation
R : GNSS, WiFi & Bluetooth
Physical Packages V : Basic (No WiFi, No GNSS,
C: Plain Model No Bluetooth, No embedded GOB
N: Color Display FKP
Q: Color Display LKP
Channel Information
8: Variable/Programmable Channel Spacing
w/ unique # of channels
9: Variable/Programmable Channel Spacing
Figure 1-4. Portable Radio Model Numbering Scheme

1-6 Introduction: Model Charts
1.4 Model Charts

1.4.1 VHF Model Chart
DP4000e Series, VHF, 136–174 MHz

Model Description
MDH56JDN9RA1AN DP4801e, 136–174 MHz, 5W, FKP, GNSS, Bluetooth, WiFi
MDH56JDN9VA1AN DP4800e, 136–174 MHz, 5W, FKP
MDH56JDQ9RA1AN DP4601e 136–174 MHz, 5W LKP GNSS BT WiFi
MDH56JDQ9VA1AN DP4600e 136–174 MHz, 5W LKP
MDH56JDC9RA1AN DP4401e, 136–174 MHz, 5W, NKP, GNSS, Bluetooth, WiFi
MDH56JDC9VA1AN DP4400e, 136–174 MHz, 5W, NKP
Item Description
X PMLD4727_S BC Kit, 136–174 MHz, 5W, FKP with GNSS
X PMLD4776_S BC Kit, 136–174 MHz, 5W, FKP
X WAED4463_ BC KIT 136–174 MHz, 5W, FKP, Cyrillic, GNSS, BT, WiFi
X WAED4464_ BC KIT 136–174 MHz, 5W, FKP, Cyrillic
X WAED4465_ BC KIT 136–174 MHz, 5W, FKP, Arabic, GNSS, BT, WiFi
X WAED4466_ BC KIT 136–174 MHz, 5W, FKP, Arabic
X WAED4467_ BC KIT 136–174 MHz, 5W, FKP, Hebrew, GNSS, BT, WiFi
X WAED4468_ BC KIT 136–174 MHz, 5W, FKP, Hebrew
X PMLD4832_S BC Kit, 136–174 MHz, 5W, LKP with GNSS
X PMLD4834_S BC Kit, 136–174 MHz, 5W, LKP
X PMLD4729_S BC Kit, 136–174 MHz, 5W, NKP with GNSS
X PMLD4777_S BC Kit, 136–174 MHz, 5W, NKP
X PMLN7322_ VHF Front Cover Kit, Roman Keypad
X PMLN7360_ VHF Front Cover Kit, Roman Keypad, GNSS
X PMLN7385_ VHF Front Cover Kit, Arabic Keypad, GNSS
X PMLN7386_ VHF Front Cover Kit, Arabic Keypad
X PMLN7387_ VHF Front Cover Kit, Cyrillic Keypad, GNSS
X PMLN7388_ VHF Front Cover Kit, Cyrillic Keypad
X PMHN4338_ VHF Front Cover Kit, Hebrew Keypad, GNSS
X PMHN4339_ VHF Front Cover Kit, Hebrew Keypad
X PMLN7419_ VHF Front Cover Kit, LKP, GNSS
X PMLN7420_ VHF Front Cover Kit, LKP
X PMLN7361_ VHF Front Cover Kit, NKP, GNSS
X PMLN7323_ VHF Front Cover Kit, NKP
X X X X X X PMAD4117_ VHF Helical Antenna (136–155 MHz)
X X X X X X PMAD4119_ VHF Stubby Antenna (136–148 MHz)
Introduction: Model Charts 1-7
DP4000e Series, VHF, 136–174 MHz (Continued)

Model Description
X X PMLN7394_S MPT Option Board Kit
X X X X X X PMLN7395_S Connect Plus Option Board Kit
1.4.2 UHF Model Chart
DP4000e Series, UHF, 403–527 MHz

Model Description
MDH56RDN9RA1AN DP4801e, 403–527 MHz, 4W, FKP, GNSS, Bluetooth, WiFi
MDH56RDN9VA1AN DP4800e, 403–527 MHz, 4W, FKP
MDH56RDQ9RA1AN DP4601e, 403–527 MHz, 4W, LKP, GNSS, Bluetooth, WiFi
MDH56RDQ9VA1AN DP4600e, 403–527 MHz, 4W, LKP
MDH56RDC9RA1AN DP4401e, 403–527 MHz, 4W, NKP, GNSS, Bluetooth, WiFi
MDH56RDC9VA1AN DP4400e, 403–527 MHz, 4W, NKP
Item Description
X PMLE5064_S BC Kit, 403–527 MHz, 4W, FKP with GNSS
X PMLE5088_S BC Kit, 403–527 MHz, 4W, FKP
X WAEE4502_ BC Kit, 403–527 MHz, 4W, FKP, Cyrillic, GNSS, BT, WiFi
X WAEE4503_ BC Kit, 403–527 MHz, 4W, FKP, Cyrillic
X WAEE4504_ BC Kit, 403–527 MHz, 4W, FKP, Arabic, GNSS, BT, WiFi
X WAEE4505_ BC Kit, 403–527 MHz, 4W, FKP, Arabic
X WAEE4506_ BC Kit, 403–527 MHz, 4W, FKP, Hebrew, GNSS, BT, WiFi
X WAEE4507_ BC Kit, 403–527 MHz, 4W, FKP, Hebrew
X PMLE5148_S BC Kit, 403–527 MHz, 4W, LKP with GNSS
X PMLE5050_S BC Kit, 403–527 MHz, 4W, LKP
X PMLE5066_S BC Kit, 403–527 MHz, 4W, NKP with GNSS
X PMLE5090_S BC Kit, 403–527 MHz, 4W, NKP
X PMLN7426_ UHF Front Cover Kit, Roman Keypad
X PMLN7427_ UHF Front Cover Kit, Roman Keypad, GNSS
X PMLN7430_ UHF Front Cover Kit, Arabic Keypad, GNSS
X PMLN7431_ UHF Front Cover Kit, Arabic Keypad
X PMLN7428_ UHF Front Cover Kit, Cyrillic Keypad, GNSS
X PMLN7429_ UHF Front Cover Kit, Cyrillic Keypad
X PMHN4350_ UHF Front Cover Kit, Hebrew Keypad, GNSS
X PMHN4351_ UHF Front Cover Kit, Hebrew Keypad
X PMLN7452_ UHF Front Cover Kit, LKP, GNSS
X PMLN7453_ UHF Front Cover Kit, LKP
X PMLN7361_ UHF Front Cover Kit, NKP, GNSS
X PMLN7323_ UHF Front Cover Kit, NKP
X X X X X X PMAE4069_ UHF Stubby Antenna 403–450 MHz
X X X X X X PMAE4079_ UHF Slim Whip Antenna 403–527 MHz
X X PMLN7394_S MPT Option Board Kit
X X X X X X PMLN7395_S Connect Plus Option Board Kit
Introduction: Model Charts 1-9
1.4.3 300 MHz Band Model Chart
DP4000e Series, 300 MHz Band, 300–360 MHz

Model Description
MDH56KDN9RA1AN DP4801e, 300–360 MHz, 4W, FKP, GNSS, BT, WiFi
MDH56KDC9RA1AN DP4401e, 300–360 MHz, 4W, NKP, GNSS, BT, WiFi
Item Description
X PMLD4794_S BC Kit, 300–360 MHz, 4W, FKP, GNSS, BT
X PMLD4796_S BC Kit, 300–360 MHz, 4W, NKP, GNSS. BT
X PMLN7427_ 300 MHz Front Cover Kit, Roman Keypad, GNSS
X PMLN7361_ 300 MHz Front Cover Kit, NKP, GNSS
X X PMAD4137_ Stubby Antenna (300–337MHz)
X X PMAD4135_ Stubby Antenna (320–360MHz)
X X PMAD4138_ VHF Whip Antenna (300–360MHz)
1.4.4 350 MHz Band Model Chart
DP4000e Series, 350 MHz Band, 350–400 MHz

Model Description
MDH56NDN9RA1AN DP4801e, 350–400 MHz, 4W, FKP, GNSS, BT, WiFi
MDH56NDC9RA1AN DP4401e, 350–400 MHz, 4W, NKP, GNSS, BT, WiFi
Item Description
X PMLD4753_S BC Kit, 350–400 MHz, 4W, FKP, GNSS, BT, WiFi
X PMLD4754_S BC Kit, 350–400 MHz, 4W, NKP, GNSS, BT, WiFi
X PMLN7427_ 350 MHz Front Cover Kit, Roman Keypad, GNSS
X PMLN7361_ 350 MHz Front Cover Kit, NKP, GNSS
X X PMAD4139_ VHF Whip Antenna (350–400 MHz)
X X PMAD4136_ Stubby Antenna (350–380 MHz)
X X PMAD4133_ Stubby Antenna (360–400 MHz)
Introduction: Specifications 1-11
1.5 Specifications
General Full Keypad Limited Keypad Non Keypad
DP4800e/ DP4601e/ DP4400e/
DP4801e DP4600e DP4401e
Channel Capacity 1000 1000 32
Frequency VHF: 136 – 174 MHz

UHF: 403 – 527 MHz
300 MHz Band: 300 – 360 MHz
350 MHz Band: 350 – 400 MHz
Dimensions (HxWxT) w/ PMNN4406_ Core 130.3 x 55.2 x 130.3 x 55.2 x 130.3 x 55.2 x
Slim Li-Ion (1500 mAH) 35.8 mm 34.3 mm 34.3 mm
Weight (w/ PMNN4493_ IMPRES Low Volt

Li-Ion (1500 mAH) 347g 322g 322g
(w/ PMNN4489_ IMPRES TIA 4950 Hi-Cap
Li-Ion (2900 mAH) 402g 377g 377g
(w/ PMNN4491_ Slim IMPRES (2100 mAH) 325g 300g 300g
Power Supply 7.5V nominal
Average battery life at 5/5/90 duty cycle with battery saver enabled in carrier squelch and transmitter
in high power.
Core Slim Li-Ion (1650 mAH) Analog: 11.5 hrs Analog: 11.5 hrs Analog: 11.5 hrs
Digital: 15.5 hrs Digital: 15.5 hrs Digital: 15.5 hrs
IMPRES Hi-Cap Li-ion Analog: 16.0 hrs Analog: 16.0 hrs Analog: 16.0 hrs
Non-FM (2250 mAH) Digital: 21.0 hrs Digital: 21.0 hrs Digital: 21.0 hrs
IMPRES Low Volt Hi-Cap Analog: 21.5 hrs Analog: 21.5 hrs Analog: 21.5 hrs
Li-ion (3000 mAH) Digital: 28.0 hrs Digital: 28.0 hrs Digital: 28.0 hrs
IMPRES TIA 4950 Hi-Cap Li-Ion (2900 Analog: 20.5 hrs Analog: 20.5 hrs Analog: 20.5 hrs
mAH) Digital: 27.0 hrs Digital: 27.0 hrs Digital: 27.0 hrs
IMPRES Li-Ion (2050 mAH) Analog: 14.5 hrs Analog: 14.5 hrs Analog: 14.5 hrs
IMPRES Hi-Cap Li-Ion FM (2300 mAH) Analog: 16.0 hrs Analog: 16.0 hrs Analog: 16.0 hrs
IMPRES Hi-Cap Li-Ion TIA4950 (2500 Analog: 17.5 hrs Analog: 17.5 hrs Analog: 17.5 hrs
mAH) Digital: 23.5 hrs Digital: 23.5 hrs Digital: 23.5 hrs
TIA 4950 UL Approval

MOTOTRBO DP4000e Series portable radios is certified by UL to standards ANSI/TIA 4950 and
CAN/CSA C22.2 No. 157-92 as intrinsically safe for use in Class I, II, III, Division 1, Groups C, D, E,
F, G, when properly equipped with a Motorola UL approved battery option. They are also approved
for use in Class I, Division 2, Groups A, B, C, D.
NOTE Weight can have 5% margin of error

1-12 Introduction: Specifications
Receiver Full Keypad Limited Keypad Non Keypad

DP4800e/ DP4601e/ DP4400e/
DP4801e DP4600e DP4401e
Frequencies VHF: 136 – 174 MHz

UHF: 403 – 527 MHz
300 MHz: 300 – 360 MHz
350 MHz Band: 350 – 400 MHz
Channel Spacing 12.5 kHz/ 20 kHz*/ 25 kHz
Frequency Stability (-30°C to +/-0.5 ppm

+60°C)
Analog Sensitivity (12 dB SINAD) 0.23 μV (0.17 μV typical) for VHF/ 300/350 MHz/ UHF
Digital Sensitivity (5% BER) 0.18 μV (0.14 μV typical) for VHF/ 300/350 MHz/ UHF
Intermodulation (TIA603C/D) 70 dB
Adjacent Channel Selectivity

TIA603 60 dB @ 12.5 kHz, 70 dB @ 20 kHz*/ 25 kHz
TIA603C/D 45 dB @ 12.5 kHz, 70 dB @ 20 kHz*/ 25 kHz
Spurious Rejection (TIA603C/D) 70 dB
Rated Audio 0.5 W
Audio Distortion @ Rated Audio 5% (typical)
Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20 kHz*/ 25 kHz
Audio Response TIA603C/D
Conducted Spurious Emission -57 dBm

(TIA603C/D)
*20kHz not supported by 300/350 MHz Band

Transmitter Full Keypad Limited Keypad Non Keypad

DP4800e/ DP4601e/ DP4400e/
DP4801e DP4600e DP4401e
Frequencies VHF: 136 – 174 MHz

UHF: 403 – 527 MHz
300 Mhz: 300 – 360 MHz
350 MHz Band: 350 – 400 MHz
Channel Spacing 12.5 kHz/ 20 kHz*/ 25 kHz
Frequency Stability (-30°C to +/-0.5 ppm

+60°C)
Power Output (Low Power) VHF/UHF: 0.5 W

300/350 MHz Band: 1 W
Power Output (High Power) VHF: 5 W

UHF: 4 W
300/350 MHz Band: 4 W
Modulation Limiting +/-2.5 kHz @ 12.5 kHz

+/-4.0 kHz @ 20 kHz*
+/-5.0 kHz @ 25 kHz
FM Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20 kHz/ 25 kHz
Conducted / Radiated Emission -36 dBm < 1 GHz

-30 dBm > 1 GHz
Adjacent Channel Power 60 dB @ 12.5 kHz

70 dB @ 20 kHz*/ 25 kHz
Audio Response TIA603C/D
Audio Distortion 3%
FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E
4FSK Digital Modulation 12.5 kHz Data Only: 7K60F1D & 7K60FXD
12.5 kHz Data & Voice: 7K60F1E & 7K60FXE
Combination of 12.5 kHz Voice and Data: 7K60F1W
Digital Vocoder Type AMBE+2™
Digital Protocol ETSI-TS102361-1

ETSI-TS102361-2
ETSI-TS102361-3
*20kHz not supported by 300/350 Mhz Band

Conforms to:
ETSI TS 102 361 (Parts 1, 2 & 3) - ETSI DMR
Standard UHF Self-Quieter Frequencies
ETSI EN 300 086 - ETSI RF Specifications (Analog)
ETSI EN 300 113 - ETSI RF Specifications (Digital) 417.6
1999/5/EC (R&TTE - Radio and Telecommunications
Terminal Equipment) 422.4
2002/95/EC (RohS - Banned Substances)
2002/96/EC (WEEE - Waste Electrical and Electronic 432
Equipment)
94/62/EC (Packaging and Packaging Waste) 436.8
Radio meets applicable regulatory requirements. 451.2

460.8
VHF Self-Quieter Frequencies
470.4
138
475.2
139.2
480 ± 5kHz
144
484.8
148.8
489.6
150
499.2
151.17 ± 5kHz
500 ± 5kHz
153.6
504
156
504.32
158.4
505.345
160 ± 5kHz
508.8
162
514.56
163.2
518.4
168
519.25
172.8
174
300 MHz Band Self-Quieter 350 MHz Band Self-Quieter

Frequencies Frequencies
302.4 ± 10kHz 350.4 ± 10kHz
307.2 ± 10kHz 355.2 ± 10kHz
312 ± 10kHz 360 ± 10kHz
316.8 ± 10kHz 364.8 ± 10kHz
321.6 ± 10kHz 369.6 ± 10kHz
326.4 ± 10kHz 374.4 ± 10kHz
331.2 ± 10kHz 379.2 ± 10kHz
336 ± 10kHz 384 ± 10kHz
340.8 ± 10kHz 388.8 ± 10kHz
345.6 ± 10kHz 393.6 ± 10kHz
350.4 ± 10kHz 396 ± 10kHz
355.2 ± 10kHz 398.4 ± 10kHz
360 ± 10kHz
GNSS/GPS Full Keypad Limited Keypad Non Keypad

DP4800e/ DP4601e/ DP4400e/
DP4801e DP4600e DP4401e
TTFF (Time To First Fix) Cold Start ≤ 60 seconds
TTFF (Time To First Fix) Hot Start ≤ 10 seconds
Horizontal Accuracy < 5 meters
Accuracy specs are for long-term tracking (95th percentile values > 5 satellites visible at a nominal
-130 dBm signal strength)
Bluetooth® Full Keypad Limited Keypad Non Keypad

DP4800e/DP4801e DP4601e/DP4600e DP4400e/DP4401e
Version Supports Bluetooth 4.0LE + EDR Specification
Range Class 2, 10 meters

Military Standards
Applicable 810C 810D 810E 810F 810G*
MIL–STD
Metho Proce- Meth Proce- Method Proce- Meth- Proce- Meth- Prode-
ds dures ods dures s dures ods dures ods cures
Low Pressure 500.1 I 500.2 II 500.3 II 500.4 II 500.5 II
High 501.1 I, II 501.2 I/A1,II/ 501.3 I/A1, II/ 501.4 I/Hot, 501.5 I/A1, II/
Temperature A1 A1 II/Hot A1
Low 502.1 I 502.2 I/C3, II/ 502.3 I/C3, II/ 502.4 I/C3, II/ 502.5 I/C3, II/
Temperature C1 C1 C1 C1
Temperature 503.1 I 503.2 A1/C3 503.3 A1/C3 503.4 I 503.5 I-C
Shock
Solar 505.1 II 505.2 I/Hot- 505.3 I/Hot- 505.4 I/Hot- 505.5 I/A1
Radiation Dry Dry Dry
Rain 506.1 I, II 506.2 I, II 506.3 I,II 506.4 I, III 506.5 I, III
Humidity 507.1 II 507.2 II/Hot- 507.3 II/Hot- 507.4 – 507.5 I/Hot-
Humid Humid Humid
Salt fog 509.1 I 509.2 I 509.3 I 509.4 – 509.5 –
Dust 510.1 I, II 510.2 I, II 510.3 I, II 510.4 I, II 510.5 I, II
Vibration 514.2 VIII/Cat 514.3 I/ 514.4 I/Cat10, 514.5 I/Cat24 514.6 I/Cat24,
F, Curve- Cat10, II/Cat3 II/Cat5 II/Cat5
W, XI II/Cat3
Shock 516.2 I, II 516.3 I, IV 516.4 I, IV 516.5 I, IV 516.6 I, IV
NOTE *Tested to MIL standard G which supersedes previous version

Environmental Specifications
Operating Temperature* -30 °C to +60 °C
Storage Temperature -40 °C to +85 °C
Thermal Shock Per MIL-STD
Humidity Per MIL-STD
ESD IEC 61000-4-2 Level 4
Dust and Water Intrusion IEC 60529 -IP68, 6.6 ft (2 m) for 2 hours
Salt Fog Per MIL-STD
Packaging Test MIL-STD 810E and D
*Operating temperature specification with LiIon battery is -10 °C to +60 °C.

Operating temperature specification with NiMH battery is -20 °C to +60 °C.
NOTE This product meets IP*68 as defined by Motorola Solutions ie submersion to a depth of 2
meters for 2 hours duration in tap water (or any source of clean freshwater)
*The IP (Ingress Protection) rating is an international standard for gauging the level of
resistance of dust and water intrusion of a device. The first digit in the two-digit IP code
provides information on the level of protection against solid objects, including dust. The
second digit indicates the resistance against water intrusion. The IP rating specified in
Motorola Solutions’ devices are certified and independently tested to meet this standard.
These devices are tested in accordance with the IP standard and with appropriate ports
and external electrical connections being firmly closed by covers, bumpers or external
antenna. Minor discoloration on electrical contact surfaces can be expected with no impact
to functional performance. Abuse and improper use of devices will invalidate warranty
claims. For more information, see specific device basic operation manual and service
manual.
Chapter 2 Test Equipment and Service Aids
2.1 Recommended Test Equipment

The list of equipment contained in Table 2-1 includes most of the standard test equipment required
for servicing Motorola portable radios.
Table 2-1. Recommended Test Equipment
Equipment Characteristics Example Application

Service Can be used as a Aeroflex 3920 Frequency/deviation meter and
Monitor substitute for items (www.aeroflex.com), signal generator for wide-range
marked with an asterisk troubleshooting and alignment
(*)
Digital RMS 100 µV to 300 V Fluke 179 or equivalent AC/DC voltage and
Multimeter * 5 Hz to 1 MHz (www.fluke.com) current measurements. Audio
10 Mega Ohm Impedance voltage measurements
RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements

Generator * -130 dBm to +10 dBm (www.agilent.com),
FM Modulation 0 kHz to Ramsey RSG1000B
10 kHz (www.ramseyelectronics.com), or
Audio Frequency 100 Hz equivalent
to 10 kHz
Oscilloscope * 2 Channel Leader LS8050 Waveform measurements

50 MHz Bandwidth (www.leaderusa.com),
5 mV/div to 20 V/div Tektronix TDS1001b
(www.tektronix.com),
or equivalent
Power Meter 5% Accuracy Bird 43 Thruline Watt Meter Transmitter power output
and Sensor * 100 MHz to 500 MHz (www.bird-electronic.com) or measurements
50 Watts equivalent
RF Millivolt 100 mV to 3 V RF Boonton 92EA RF level measurements

Meter 10 kHz to 1 GHz (www.boonton.com) or equivalent
Power Supply 0 V to 32 V B&K Precision 1790 Voltage supply

0 A to 20 A (www.bkprecision.com)
or equivalent
2-2 Test Equipment and Service Aids Service Aids
2.2 Service Aids

Table 2-2 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-2. Service Aids
Motorola
Description Application
Part No.
RLN4460_ Portable Test Set Enables connection to the audio/accessory jack.
Allows switching for radio testing.
GMVN5141_ Customer Programming Allows servicer to program radio parameters, tune

Software on CD-ROM and troubleshoot radios.
PMKN4012B* Portable Programming Cable This cable connects the radio to a USB port for radio
programming and data applications.
PMKN4013C* Portable Programming, Testing & This cable connects the radio to a USB port for radio
Alignment Cable programming, testing and alignment.
PMNN4428_ 7.5V Universal Battery Eliminator Connects to radio via battery eliminator cable.
PMLN6154_ RF Adaptor Adapts radio’s antenna port to SMA cabling of test

equipment.
PMLN6422_ RF Cable This cable measures RF related measurements.
TL000015A01 Chassis and Knob Opener Enables the removal of chassis from radio housing.
PMLN6155_ RF Adaptor Holder Holds RF connector to radio.
NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages.
NTN4265_ Pressure Pump Kit Allows servicer to locate leakages.
5871134M01 Connector Fitting This connector allows the vacuum hose to be

connected to the radio chassis.
3271133M01 Fitting Seal This seal secures the connector fitting to the radio
chassis.
* Earlier versions of programming cables will not work with the radio.
Test Equipment and Service Aids Programming, Testing and Alignment Cable 2-3
2.3 Programming, Testing and Alignment Cable

#25 #14
#1 #4
P1 #13 #1
P2
P3
#1 #2
#11
#12
Figure 2-1. Programming, Testing and Alignment Cable

2-4 Test Equipment and Service Aids Programming, Testing and Alignment Cable
Table 2-3. Pin Configuration of Side Connector
CONNECTION
P1 P2 P3
Pin Pin Pin Function

1 GROUND
1 3 VCC (5V)
3 4 DATA+
2 5 DATA-
16 4 6 GROUND
1&5 7 EXTERNAL SPEAKER+
2&7 8 EXTERNAL SPEAKER-
20 9 EXTERNAL PTT
17 10 EXTERNAL MIC+
16 11 EXTERNAL MIC-
slot for accessory

GPIO_0 connector hook
1-Wire
Vbus
D+
1
2
D- 3
4
GND 5
6
Spkr +
7
8
9
Spkr - 10
11
GPIO_3 12
Mic +
Mic -
GPIO_4
Figure 2-2. Pin Layout of Side Connector

Chapter 3 Transceiver Performance Testing
3.1 General
These radios meet published specifications through their manufacturing process by utilizing high-
accuracy laboratory-quality test equipment. The recommended field service equipment approaches
the accuracy of the manufacturing equipment with few exceptions. This accuracy must be
maintained in compliance with the manufacturer’s recommended calibration schedule.
Although these radios function in digital and analog modes, all testing is done in analog mode.
3.2 Setup
Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.
Do NOT use any form of connector, e.g. wires, crocodile

clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number Title
3-2 Front Panel Access Test Mode Displays
3-3 Test Environments
3-4 Test Frequencies
3-6 Transmitter Performance Checks
3-7 Receiver Performance Checks
Table 3-1. Initial Equipment Control Settings
Service Monitor Power Supply Test Set

Monitor Mode: Power Monitor Voltage: 7.5Vdc Speaker set: A
RF Attn: -70 DC on/standby: Speaker/load:

Standby Speaker
AM, CW, FM: FM Volt Range: 10V PTT: OFF

3-2 Transceiver Performance Testing Setup
Table 3-1. Initial Equipment Control Settings
Service Monitor Power Supply Test Set

Oscilloscope Source: Mod Current: 2.5A
Oscilloscope Horizontal: 10mSec/Div
Oscilloscope Vertical: 2.5kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: Middle setting
Monitor Vol: 1/4 setting
Transceiver Performance Testing Setup 3-3
Setup:
Set up the DMR Transmitter and Receiver Test as per Figure 3-1.
a. Connect the Programming cable to the radio and to the computer.
b. Remove RF plug (orange) as shown in Figure 4.5, on page 4-3
c. Connect the RF antenna adaptor to the 50 Ohm RF Input/Output port of the radio.
Connect the other end of the RF antenna adaptor to the T/R port of the Radio Test Set 3920 using
the RF cable shown in Figure 3-1.
See “RF Adaptor Assembly” on page 4-3 for complete RF Adaptor Assembly steps.
Ant. Input / Output
T/R Port
Programming Cable
Modulated RF Test
Signal / Tx
modulated RF Signal Battery Eliminator
Power Supply
Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup

3-4 Transceiver Performance Testing Display Model Test Mode
3.3 Display Model Test Mode

3.3.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within 10 seconds after Self Test is complete, press Side Button 2 five times in succession
3. The radio beeps and will show a series of displays that will give information regarding various
version numbers and subscriber specific information. The displays are described in Table 3-2.
Table 3-2. Front Panel Access Test Mode Displays
Name of Display Description Appears

Service Mode The literal string indicates the radio has entered test mode. Always
Host Version The version of host firmware. Always
DSP Version The version of DSP firmware. Always
Model Number The radio’s model number as programmed in the codeplug. Always
MSN The radio’s serial number as programmed in the codeplug. Always
FLASHCODE The FLASH codes as programmed in the codeplug. Always
RF Band The radio’s band. Always
NOTE The radio stops at each display for 2 seconds before moving to the next information display.
If the information cannot fit into 1 line, the radio display scrolls automatically character by
character after 1 second to view the whole information. If the Left Navigation Key () is
pressed before the last information display, the radio shall suspend the information display
until the user presses Right Navigation Key () to resume the information display. The
radio beeps for each button press. After the last display, RF Test Mode will be displayed.
3.3.2 LCD Flicker Test Mode

1. Press and hold side button 1 to access the flicker test. A black screen will appear on the
display.
2. The screen will remain black for a properly functioning display.
3. If there is any flickering, send to the service depot to be fixed.
4. Press and hold side button one for 2 seconds to be taken to the LCD Display test mode.
3.3.3 LCD Display Test Mode

1. Press any button to test the LCD display, press button  until the display are fixed. Then,
press and hold the first side button until the screen change.
2. Upon key press, the housing shall display a White screen with 2 pixels wide of a black
border inset from the edge by 2 pixels and the text "Display Test Mode" in black.
3. Upon key press, the housing shall display a Black screen with 2 pixels wide of a White
boarder inset from the edge by 2 pixels and the text "Display Test Mode" in White.
4. Upon key press, the housing shall display a full screen in Red.
Transceiver Performance Testing Display Model Test Mode 3-5
5. Upon key press, the housing shall display a full screen in Green.
6. Upon key press, the housing shall display a full screen in Blue.
7. Upon key press, the housing shall display the growing horizontal bars with a cyclic color of
Red>Green>Blue>Black>Red>Green>Blue>Black>Red (Full Screen).
8. Upon key press, the housing shall display the growing vertical bars with a cyclic color of
Red>Green>Blue>Black>Red>Black (Full Screen).
3.3.4 RF Test Mode

When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or air test.
In RF Test Mode, the display upon the first line is “RF Test”, together with the power level icon at the
right end of the first line. The display upon the second line is the test environment, the channel
number and channel spacing. The default test environment is CSQ.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-3.
Table 3-3. Test Environments
No. of
Description Function
Beeps
1 Carrier Squelch RX: if carrier detected
(CSQ) TX: mic audio
2 Tone Private-Line RX: unsquelch if carrier and tone detected

(TPL) TX: mic audio + tone
3 Digital Mode RX: if carrier detected

(DIG) TX: mic audio
4 Unsquelch RX: constant unsquelch

(USQ) TX: mic audio
2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz
and 20 kHz as. The radio beeps once when radio toggles to 20kHz, beeps twice for 25 kHz
and beeps three times for 12.5 kHz.
3. Turning of the Channel Knob changes the test channel from 1 to 16 as described in
Table 3-4. The radio beeps in each position.
Table 3-5. Test Frequencies
Channel
300 350
Selector Test
UHF VHF MHz MHz
Switch Channel
Band Band
Position
1 Low Power TX#1 or #9 403.15 136.075 300.025 350.025
9 High Power RX#1 or #9 403.15 136.075 300.025 350.025
2 Low Power TX#2 or #10 423.25 142.575 308.525 357.525

10 High Power RX#2 or #10 423.25 142.575 308.525 357.525
3 Low Power TX#3 or #11 444.35 146.575 317.025 364.525

11 High Power RX#3 or #11 444.35 146.575 317.025 364.525
4 Low Power TX#4 or #12 465.45 155.575 325.525 371.525

12 High Power RX#4 or #12 465.45 155.575 325.525 371.525
5 Low Power TX#5 or #13 485.55 161.575 334.025 378.525

13 High Power RX#5 or #13 485.55 161.575 334.025 378.525
6 Low Power TX#6 or #14 506.65 167.575 342.525 385.525

14 High Power RX#6 or #14 506.65 167.575 342.525 385.525
7 Low Power TX#7 or #15 526.75 173.975 351.025 392.525

15 High Power RX#7 or #15 526.75 173.975 351.025 392.525
8 Low Power TX#8 or #16 527.00 174.000 359.925 399.925

16 High Power RX#8 or #16 527.00 174.000 359.925 399.925
Table 3-6. Transmitter Performance Checks
Communications
Test Name Radio Test Set Comments
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test Test Channel 4 continuously ±68Hz for VHF
frequency* carrier squelch transmit ±150 Hz for 300 MHz
Monitor: Frequency (during the Band
error performance ±175 Hz for 350 MHz
Input at RF In/Out check) Band
±201Hz for UHF
Power RF As above As above As above Low Power:

0.9 – 1.5W (VHF/300/
MHz Band/UHF)High
Power:
4.0 – 4.8W (UHF/300/
MHz Band)High
Power:
5.0 – 5.8W (VHF)
Voice Mode: PWR MON As above As above, meter Deviation:

Modulation 4th channel test selector to mic ≥ 4.0 kHz but ≤ 5.0
frequency* kHz (25 kHz Ch Sp).
atten to -70, input to RF
In/Out
Monitor: DVM: AC Volts
Set 1kHz Mod Out level
for 0.025Vrms at test
set,
80mVrms at AC/DC
test set jack
Voice Mode: PWR MON TEST MODE, Remove Press PTT switch on
Modulation 4th channel test Test Channel 4 modulation input radio. Say “four”
(internal) frequency* carrier squelch loudly into the radio
atten to -70, input to RF output at mic. Measure
In/Out antenna deviation:
≥ 4.0 kHz but ≤ 5.0
kHz (25 kHz Ch Sp)
TPL As above TEST MODE, As above Deviation:

Modulation 4th channel test Test Channel 4 ≥500Hz but ≤1000Hz
frequency* TPL (25 kHz Ch Sp).
BW to narrow
RF Power DMR mode. Slot 1 TEST MODE, Key up radio TTR Enable is
Power and Slot 2 Digital Mode, without modulation needed and IFR to be
Power transmit using Tuner set to trigger mode
without with signal level
modulation ~1.5V
Table 3-6. Transmitter Performance Checks (Continued)
Communications
Analyzer
FSK Error DMR Mode. FSK Error TEST MODE, Key up radio with Not Exceed 5%
Digital Mode, O513 test pattern
transmit with modulation using
O153 test Tuner
pattern
Magnitude DMR Mode. Magnitude As above As above Not Exceed 1%

Error error
Symbol DMR Mode. Symbol As above As above Symbol Deviation

Deviation Deviation should be within
648Hz +/- 10% and
1944Hz +/- 10%
Transmitter DMR Mode As above As above Transmitter BER

BER should be 0%
* See Table 3-4
Table 3-7. Receiver Performance Checks
Communications
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test Test Channel 4 continuously ±68Hz for VHF
frequency* carrier squelch transmit ±150 Hz for 300 MHz
Monitor: Frequency error output at (during the Band
Input at RF In/Out antenna performance ±175 Hz for 350 MHz
check) Band
±201Hz for UHF
Rated Audio Mode: GEN TEST MODE PTT to OFF Set volume
Output level: 1.0mV RF Test Channel 6 (center), meter control to 2.83 Vrms
6th channel test carrier squelch selector to Audio
frequency* PA
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts
Distortion As above, except to As above As above Distortion <3.0%
distortion
Sensitivity As above, except SINAD, As above PTT to OFF RF input to be
(SINAD) lower the RF level for (center) <0.23μV for VHF/300/
12dB SINAD. 350 MHz/UHF
Noise RF level set to 1mV RF As above PTT to OFF Set volume
Squelch (center), meter control to 2.83Vrms
Threshold selection to Audio
(only radios PA, speaker/load
with to speaker
conventional As above, except change Out of TEST As above Unsquelch to occur at
system need frequency to a MODE; select <0.25μV.
to be tested) conventional system. a conventional Preferred SINAD = 9
Raise RF level from zero system – 10dB
until radio unsquelches.
Receiver IFR DMR mode. Signal Test Mode, Read BER using RF level to be
BER generator with 1031 test Digital Mode, Tuner. Adjust RF <0.35μV for 5% BER
pattern receive 1031 level to get 5%
test pattern BER
Receiver IFR DMR Mode. Signal Test Mode, RF level = -47dBm. Adjust volume until
Rated Audio generator with 1031 test Digital Mode, Set audo analyzer Vrms = 2.83V
pattern receive 1031 to read Vrms.
test pattern Adjust volume to
get rated audio
Receiver IFR DMR Mode. Signal As above As above. Then set Not exceed 5%
Audio generator with 1031 test audio analyzer to
Distortion pattern measure distortion
* See Table 3-4

3.3.5 LED Test Mode

1. Press and hold Side Button 1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button/key press, the radio lights the red LED and displays “Red LED On”.
3. Consequently, upon any button/key press, the red LED is turned off and the radio lights the
green LED and displays “Green LED On”.
4. Upon any successive button/key press, the green LED is turned off, and the radio shall light
both LEDs up while displaying “Both LEDs On”. Since there is only one LED on the portable,
the LED color will be orange when the radio lights both LEDs.
3.3.6 Accelerometer Test

1. Long press Side Button 1, the radio will enter accelerometer test mode and the display will
show Accelerometer Test Mode.
2. Hold the radio horizontally and press OK button
3. The display will show Accelerometer Test Passed or Accelerometer Test Failed accordingly.
3.3.7 Backlight Test Mode

1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once and displays
“Backlight Test Mode”.
2. The radio turns on both LCD and keypad backlight together.
3.3.8 Speaker Tone Test Mode

1. Press and hold Side Button 1 after Backlight Test Mode. The radio beeps once and displays
“Speaker Tone Test Mode”.
2. The radio generates a 1 KHz tone with the internal speaker.
3.3.9 Earpiece Tone Test Mode

1. Press and hold Side Button 1 after Speaker Tone Test Mode. The radio beeps once and
displays “Earpiece Tone Test Mode”.
2. The radio generates a 1 KHz tone with the earpiece.
3.3.10 Audio Loopback Earpiece Test Mode

1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once and
displays “Audio Loopback Earpiece Test Mode”.
2. The radio shall route any audio on the external mic to the earpiece.
3.3.11 Battery Check Test Mode

1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once and momentarily displays “Battery Check Test Mode”.
2. The radio will display the following:
Rem. Capacity100%
Figure 3-2. Battery Check Test Mode Display
3.3.12 Button/Knob/PTT Test Mode

1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once and
displays “Button Test”(line 1).
2. Rotate the Volume Knob; “2/1” through “2/255” appears. The radio beeps at each position.
3. Rotate the Channel Knob; When rotate the channel knob in clockwise, “4/1” appear. When
rotate the channel knob in counter clockwise, “4/-1” appear. The radio beeps at each position.
4. Press Side Button 1; “96/1” appears & radio beeps; release, “96/0” appears & radio beeps.
5. Press Side Button 2; “97/1”appears & radio beeps; release, “97/0” appears & radio beeps.
6. Press Side Button 3; “98/1”appears & radio beeps; release, “98/0” appears & radio beeps.
7. Press the PTT Switch; “1/1” appears & radio beeps; release, “1/0” appears & radio beeps.
8. Press Top Button; “148/1” appears & radio beeps; release, “148/0” appears & radio beeps.
9. Keypad Checks:
- Press 0, “48/1” appears & radio beeps; release, “48/0” appears & radio beeps.
- Press *, “58/1” appears & radio beeps; release, “58/0” appears & radio beeps.
- Press #, “59/1” appears & radio beeps; release, “59/0” appears & radio beeps.
- Press P1, “160/1” appears & radio beeps; release, “160/0” appears & radio beeps.
- Press P2, “161/1” appears & radio beeps; release, “161/0” appears & radio beeps.
- Press MENU, “85/1” appears & radio beeps; release, “85/0” appears & radio beeps.
- Press BACK, “129/1” appears & radio beeps; release, “129/0” appears & radio beeps.
- Press , “128/1” appears & radio beeps; release, “128/0” appears & radio beeps.
- Press , “130/1” appears & radio beeps; release, “130/0” appears & radio beeps.
- Press ▲, "135/1" appears & radio beeps; release, "135/0" appears & radio beeps.
- Press ▼, "136/1" appears & radio beeps; release, "136/0" appears & radio beeps.
Transceiver Performance Testing Non-Display Model Test Mode 3-13
3.4 Non-Display Model Test Mode

3.4.1 Entering Non-Display Radio Test Mode
1. Turn the radio on.
2. Within 10 seconds after “Self Test” is complete, press Side Button 2 five times in succession.
3. The radio beeps.
3.4.2 RF Test Mode

When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or “air test”.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-3.
2. Each short press of Side Button 1 toggles the channel spacing between 25 KHz, 12.5 KHz
and 20 KHz as. The radio beeps once when radio toggles to 20KHz, beeps twice for 25KHz
and beeps three times for 12.5KHz.
3. Turning of the Channel Knob changes the test channel from 1 to 16 as described in
Table 3-4. The radio beeps in each position.
3.4.3 LED Test Mode

1. Press and hold Side Button 1 in RF Test Mode. The radio beeps once.
2. Upon any button/key press, the radio lights up the red LED.
3. Consequently, upon any button/key press, the red LED is turned off and the radio turns on the
green LED.
4. Consequently, upon any button/key press, the green LED is turned off the radio shall turn on
both LEDs.
3.4.4 Speaker Tone Test Mode

1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once.
2. The radio generates a 1 KHz tone with the internal speaker.
3-14 Transceiver Performance Testing Non-Display Model Test Mode
3.4.5 Earpiece Tone Test Mode

1. Press and hold Side Button 1 after Speaker Tone Test Mode. The radio beeps once.
2. The radio generates a 1 KHz tone with the earpiece.
3.4.6 Audio Loopback Earpiece Test Mode

1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once.
2. The radio shall route any audio on the external mic to the earpiece.
3.4.7 Battery Check Test Mode

1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once.
2. The radio LED lights up accordingly; green LED for High Battery Level, orange LED for Mid
Battery Level and blinking red LED for Low Battery Level.
3.4.8 Button/Knob/PTT Test Mode

1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once.
2. Rotate the Volume Knob; the radio beeps at each position.
3. Rotate the Channel Knob; the radio beeps at each position.
4. Press Side Button 1; the radio beeps; release, the radio beeps.
7. Press the PTT Switch; the radio beeps; release, the radio beeps.
8. Press Top Button; the radio beeps; release, the radio beeps.
Chapter 4 Radio Programming and Tuning
4.1 Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner and AirTracer applications, which are all designed for use in a Windows 8/72000/
XP environment. These programs are available in one kit as listed in Table 4-1. An Installation Guide
is also included with the kit.
NOTE Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1. Software Installation Kits Radio Tuning Setup
Description Part Number
MOTOTRBO CPS, Tuner and AirTracer Applications CD RVN5115_
4.2 Customer Programming Software Setup

The CPS programming setup, shown in Figure 4-1 is used to program the radio.
NOTE Refer to appropriate program on-line help files for the programming procedures.
! Computer USB ports can be sensitive to Electrostatic Discharge. Do not touch

exposed contacts on cable when connected to a computer.
Caution
R adio
Programming, Testing
Battery & Alignment Cable
PMKN4012B
PMKN4013C or later.
Figure 4-1. CPS Programming Setup

4-2 Radio Programming and Tuning AirTracer Application Tool
4.3 AirTracer Application Tool

The MOTOTRBO AirTracer application tool has the ability to capture over-the-air digital radio traffic
and save the captured data into a file. The AirTracer application tool can also retrieve and save
internal error logs from MOTOTRBO radios. The saved files can be analyzed by trained Motorola
personnel to suggest improvements in system configurations or to help isolate problems.
4.4 Radio Tuning Setup

A personal computer (PC), Windows 2000/XP/Windows 7and a tuner program are required to tune
NOTE Refer to appropriate program on-line help files for the programming procedures.
the radio. To perform the tuning procedures, the radio must be connected to the PC, radio interface
box (RIB), and test equipment setup as shown in Figure 4-2.
Battery Service Monitor

Eliminator or Counter
7.5V Reg. Transmit
RF Adaptor
Wattmeter
+12VDC
Power Radio 10 dB Pad Receive
Supply RF Generator
Audio In Tx Audio Generator
Test Box
RLN4460_ Rx Sinad Meter
Programming, Testing &
Alignment Cable
AC Voltmeter
PMKN4013C or later
Figure 4-2. Radio Tuning Equipment Setup

Radio Programming and Tuning RF Adaptor Assembly 4-3
4.5 RF Adaptor Assembly

1. Remove the RF plug.
RF Plug
Figure 4-3. RF Plug removal

2. Align RF Adaptor Holder to the antenna opening of the housing. The RF Adaptor Holder
should fit snugly around the outer wall of the antenna opening.
RF Adaptor
Figure 4-4. RF Adaptor holder

4-4 Radio Programming and Tuning RF Adaptor Assembly
3. Fasten the screw provided the hold the RF Adaptor in place.
Figure 4-5. RF Adaptor screw

4. Slot the RF Connector into the RF Adaptor Holder slot.
RF Connector
Figure 4-6. RF Adaptor complete assembly

Disassembly/Reassembly Procedures Introduction 5-1
Chapter 5 Disassembly/Reassembly Procedures
5.1 Introduction
This chapter provides details about the following:
• Preventive maintenance (inspection and cleaning).

• Safe handling of CMOS and LDMOS devices.
• Disassembly and reassembly of the radio.
• Repair procedures and techniques.
5.2 Preventive Maintenance

Periodic visual inspection and cleaning is recommended.
5.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.
5.2.2 Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the front
cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic
visual inspection reveals the presence of smudges, grease, and/or grime.
NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (100% by volume).
!
The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
Caution chemicals.
5-2 Disassembly/Reassembly Procedures Safe Handling of CMOS and LDMOS Devices
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
Cleaning Internal Circuit Boards and Components
Isopropyl alcohol (100%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge
embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the
dislodged material out and away from the inside of the radio. Make sure that controls or tunable
components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process
since this could cause the liquid to collect in unwanted places. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front cover or back cover.
NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
!
Use all chemicals as prescribed by the manufacturer. Be sure
to follow all safety precautions as defined on the label or
Caution material safety data sheet.
5.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent
device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION
paragraph in the Disassembly and Reassembly section of the manual.
Disassembly/Reassembly Procedures Safe Handling of CMOS and LDMOS Devices 5-3
DO NOT attempt to disassemble the radio without first referring to the following CAUTION
statement.
This radio contains static-sensitive devices. Do not open the radio unless you are
! properly grounded. Take the following precautions when working on this unit:
Caution • Store and transport all CMOS/LDMOS devices in conductive

material so that all exposed leads are shorted together. Do not insert
CMOS/LDMOS devices into conventional plastic “snow” trays used
for storage and transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the
CMOS/LDMOS device. We recommend using the Motorola Static
Protection Assembly (part number 0180386A82), which includes a
wrist strap, two ground cords, a table mat, and a floor mat, ESD
shoes and an ESD chair.
• Wear a conductive wrist strap in series with a 100k resistor to
ground. (Replacement wrist straps that connect to the bench top
covering are Motorola part number 4280385A59).
• Do not wear nylon clothing while handling CMOS/LDMOS devices.
• Do not insert or remove CMOS/LDMOS devices with power applied.
Check all power supplies used for testing CMOS/LDMOS devices to
be certain that there are no voltage transients present.
• When straightening CMOS/LDMOS pins, provide ground straps for
the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS/LDMOS devices by the package and
not by the leads. Prior to touching the unit, touch an electrical
ground to remove any static charge that you may have
accumulated. The package and substrate may be electrically
common. If so, the reaction of a discharge to the case would cause
the same damage as touching the leads.
5-4 Disassembly/Reassembly Procedures Repair Procedures and Techniques – General
5.4 Repair Procedures and Techniques – General

NOTE Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards — examples shown below) were developed and assembled using
environmentally preferred components and solder assembly techniques to comply with
the European Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/
95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/
EC. To maintain product compliance and reliability, use only the Motorola specified parts
in this manual.
Any rework or repair on Environmentally Preferred Products must be done using the appropriate
lead-free solder wire and lead-free solder paste as stated in the following table:
Table 5-1. Lead Free Solder Wire Part Number List
Motorola Part Flux Content Melting Supplier Part

Alloy Flux Type Diameter Weight
Number by Weight Point number
1088929Y01 95.5Sn/3.8Ag/ RMA 2.7-3.2% 217C 52171 0.015” 1lb

0.7Cu Version spool
Table 5-2. Lead Free Solder Paste Part Number List
Motorola Part Manufacturer Part Liquid

Viscosity Type Composition & Percent Metal
Number Number Temperature
1085674C03 NC-SMQ230 900- Type 3 (95.5%Sn-3.8%Ag- 217°C

1000KCPs (-325/ 0.7%Cu) 89.3%
Brookfield +500)
(5rpm)
Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.
When soldering near a connector:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges.
Disassembly/Reassembly Procedures Disassembling and Reassembling the Radio — General 5-5
5.5 Disassembling and Reassembling the Radio — General

When disassembling and reassembling the radio, it is important to pay particular attention to the
snaps and tabs, and how parts align with each other.
The following tools are required for disassembling the radio:
• TORX™ T4 and 6IP TORX Plus screwdriver
• Chassis and Knob Opener (TL000015A01)
The following item and tools are required for reassembling the radio:
• Grease (1185937A01)
• TORX™ T4 and 6IP TORX Plus screwdriver
• Vacuum Pump Kit (NLN9839) - Radio Immersibility Test
• Pressure Pump Kit (NTN4265) - Radio Immersibility Test
• Connector Fitting (5871134M01) - Radio Immersibility Test
• Fitting Seal (3271133M01) - Radio Immersibility Test
• Seal Port (3286058L01)
• Label Ventilation (5478220A01)
If a unit requires further testing or service than is customarily performed at the basic level, please
send the radio to a Motorola Service Center.
5-6 Disassembly/Reassembly Procedures Radio Disassembly – Detailed
5.6 Radio Disassembly – Detailed

5.6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Release the battery latch by moving it upwards.
b. Hold the latch in the release position and slide the battery out.
c. Remove the battery from the radio.
Figure 5-1. Battery removal

3. Remove the antenna by turning it counterclockwise.
Figure 5-2. Antenna removal.

Disassembly/Reassembly Procedures Radio Disassembly – Detailed 5-7
4. Remove the channel selector knob and volume knob off from their shafts using the knob
removal tool.
NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.
5. Hook the knob opener under the shroud as shown in Figure 5-3 and detach it with a
downward motion.
Shroud
Figure 5-3. Shroud removal

6. Separate the chassis from the housing assembly as follows:
a. Insert the chassis opener into the recess at the bottom of the radio. Apply a downward
force to separate the chassis from the front housing.
b. Remove the chassis from the front housing.
Chassis Opener
Figure 5-4. Chassis removal

7. Place the chassis at a 120 degree angle to facilitate removal of the 2 flex connecting the
chassis to the front housing
Figure 5-5. Chassis and Front Housing

8. Release the keypad flex from its connector.
Figure 5-6. Keypad flex removal

9. Remove the interface flex from main board by pulling it out of its connector gently.
NOTE Do not open the keypad flex by lifting it straight but by applying pressure to the side
Figure 5-7. Interface flex removal

5.6.2 Chassis Disassembly

1. Remove the 2 GOB (Generic Option Board) flexes from the mainboard.
GOB flex
Mini GOB flex
Figure 5-8. GOB and mini GOB flex removal
NOTE This step also applies to the MPT Option Board and the Connect Plus Option Board.
2. Remove the 5 screws on the mainboard using a 6IP Torx Plus screwdriver head. Separate
the mainboard from the chassis.
Figure 5-9. Mainboard removal

3. Remove the top control seal.
Figure 5-10. Top control seal removal

4. Remove the 3 screws on the GOB using a 6IP Torx Plus screwdriver head. Separate the
GOB from the chassis.
Figure 5-11. GOB removal

5. Remove the battery contact seal.
Figure 5-12. Battery contact seal removal

6. Remove the RF rubber plug.
Figure 5-13. RF rubber plug removal

7. Remove the top control seal.

5.6.3 Interface Board, Keypad Board and LCD Disassembly

1. Unlatch and remove the interface flex.
Figure 5-14. Interface flex removal

2. Disconnect the UC flex.
Figure 5-15. UC flex removal

3. Use a tweezer to disconnect the PTT flex.
Figure 5-16. PTT flex removal

4. Remove the four screws and gently lift out the interface board from the front housing.
Figure 5-17. Interface board removal
NOTE Ensure the mic boot is removed from the front housing.
5. Unlatch and remove the LCD flex. Remove the four screws holding the keypad board and lift
it out from the front housing.
Figure 5-18. Keypad board removal

6. Gently lift out the display module.
Figure 5-19. Display module removal

5.6.4 Speaker and Universal Connector Flex Disassembly

1. Peel off the UC escutcheon with a tweezer.
Figure 5-20. UC escutcheon removal

2. Gently pry out the UC flex circuit and push it into the front housing through the UC slot.
Figure 5-21. UC flex removal

3. Unscrew the single screw holding the speaker retainer assembly and remove it from the front
housing.
Figure 5-22. Speaker assembly removal

4. Remove the speaker retainer from the speaker module.
Figure 5-23. Speaker removal

5.6.5 Emergency Button Assembly Dissassembly

1. The Emergency button can be removed without the use of tools once the speaker retainer is
removed.
Figure 5-24. Emergency button removal

5.6.6 Bluetooth GPS Antenna Disassembly

1. Use a T4 head to unscrew the Bluetooth GPS antenna module and remove it by sliding out
from the front housing.
Figure 5-25. Bluetooth GPS antenna removal

Disassembly/Reassembly Procedures Radio Reassembly - Detailed 5-21
5.7 Radio Reassembly - Detailed

5.7.1 Bluetooth GPS Antenna and Emergency Button Reassembly
1. Slide in the Bluetooth GPS antenna and affix the screw.
Figure 5-26. Bluetooth GPS antenna reassembly

2. Insert the emergency button into the proper slot.
Figure 5-27. Emergency button reassembly

5-22 Disassembly/Reassembly Procedures Radio Reassembly - Detailed
5.7.2 Speaker and Universal Connector Flex Reassembly

1. Insert the UC flex circuit through the speaker retainer.
Figure 5-28. Speaker retainer reassembly

2. Seat the speaker module in the recess of the front housing and firmly screw in the speaker
retainer.
NOTE Ensure there is no unnecessary pressure is applied to the spring contact on the speaker
retainer.
3. Push the UC flex circuit through the UC slot on the front housing.
Figure 5-29. Speaker reassembly

4. Firmly stick the UC flex circuit on the housing and replace a new UC escutcheon.
Figure 5-30. UC Escutcheon replacement
NOTE Clean the area on the housing with IPA before sticking the UC flex and escutcheon.
5.7.3 Interface Board, Keypad Board and LCD Reassembly

1. Place the display module in the front housing.
Figure 5-31. Display module reassembly

2. Insert the keypad board and ensure it sits properly by using the notches on the front housing
as a guide. Connect the display module flex and affix the screws.
Figure 5-32. Keypad Board reassembly

3. Screw in the interface board. Ensure the PTT flex is on top of the interface board. Attach the
keypad flex, interface flex, PTT flex and the UC flex.
NOTE Ensure to push the interface flex in all the way and the wings are not on top of the
capacitors.
Figure 5-33. Front housing reassembly

5.7.4 Chassis Reassembly

1. Insert or replace the RF rubber plug and battery contact seal on the chassis.
Battery
Contact
Seal
RF Plug
Rubber Lip
Figure 5-34. Chassis reassembly
NOTE Ensure the rubber lip of the battery contact seal rests on top as shown in the Figure 5-34.
2. Paste the thermal pad in the designated location on the underside of the chassis.
Thermal Pad
Figure 5-35. Thermal Pad

3. Replace the top control seal.
Figure 5-36. Top control seal reassembly

4. Screw in the main board and the GOB onto the chassis and connect the two GOB flex to the
mainboard.
Figure 5-37. Main board and GOB reassembly

5.7.5 Chassis and Front Cover Reassembly

1. Connect the keypad flex and interface flex to the main board.
Figure 5-38. Main board connectors.

2. Apply grease to the full perimeter of the chassis’s O-Ring.
3. Insert top chassis tabs into the recesses on front cover and the tabs are fully inserted.
4. Gently push down the chassis into the front cover until it snaps in place.
Figure 5-39. Chassis reassembly

5. Insert knobs, antenna, shroud and battery.
5-30 Disassembly/Reassembly Procedures Ensuring Radio Immersibility
5.8 Ensuring Radio Immersibility

This section discusses radio immersibility concerns, tests, and disassembly and reassembly of the
series radios.
5.8.1 Servicing
The series radios shipped from the Motorola factory have passed vacuum testing and should be
capable of restoring the watertight integrity of the radio.
It is strongly recommended that the maintenance of the radio be deferred to
! qualified service personnel and service shops. This is of paramount importance

as irreparable damage to the radio can result from service by unauthorized
Caution persons. If disassembly is necessary, unauthorized attempts to repair the radio
may void any existing warranties or extended performance agreements with
Motorola. It is also recommended that immersibility be checked annually by
qualified service personnel/workshop that is authorized by Motorola.
5.8.2 Accidental Immersion
If the radio is accidentally dropped in water, shake the radio to remove the excess water from the
speaker grille and microphone port area before operating; otherwise, the sound may be distorted
until the water has evaporated, or is dislodged from these areas.
5.8.3 Specialized Test Equipment
This section summarizes the specialized test equipment necessary for testing the integrity of the
series radios.
To ensure that the radio is truly a watertight unit, special testing, test procedures, and specialized
test equipment are required. The special testing involves a vacuum check of the radio and pressure
testing (troubleshooting) for water leaks if the vacuum check fails. The specialized test equipment/
instrument (Table 2-2 on page 2-2) is authorized by Motorola and needed to perform the vacuum
check and pressure testing, if required. Any equipment/tools/instruments not mentioned in the table
must not be used to perform these test.
5.8.4 Vacuum Pump Kit NLN9839
The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. A connector fitting
(part number 5871134M01) and fitting seal (part number 3271133M01) pump connector, which must
be ordered separately, connects the vacuum hose to the radio’s chassis.
Fitting Seal
(part number
3271133M01)
Connector Fitting
(part number
5871134M01)
Figure 5-40. Connector Fitting - Fitting Seal Pump Connector

Disassembly/Reassembly Procedures Ensuring Radio Immersibility 5-31
5.8.5 Pressure Pump Kit NTN4265
The pressure pump kit includes a pressure pump with gauge, and a pressure hose. As with the
vacuum pump kit above, the connector fitting - fitting seal pair connects the pressure hose to the
radio’s chassis.
5.8.6 Miscellaneous Hardware
Other items needed for testing the immersibility radio include:
• Large water container

• Deionized (DI) water
• A supply of replacement parts: Battery Contact Seal, Breathing Vent Label and Breathing
Vent Membrane.
5.8.7 Vacuum Test
The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the
radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly
sealed, watertight unit. Before starting the vacuum test:
• Remove the battery.

• Remove the universal connector dustcover to expose the universal connector.
• Remove the breathing vent label and breathing vent membrane.
To conduct the vacuum test:
1. Attach antenna firmly to the radio.

2. Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by
blocking off the open end of the hose and operating the pump a few times. The actual reading
of the gauge at this point is not important; it is important that the gauge pointer remained
steady, indicating no vacuum leaks in the pump.
3. Ensure that the fitting seal is attached to the hose-to-chassis pump connector. Screw the
pump connector into the tapped hole in the chassis.
! Please do not bend or over tighten pump connector to the chassis.

Caution
4. Attach the open end of the hose to the pointed end of the pump connector.
5. Place the radio on a flat surface with the chassis facing upward.
6. Operate the pump until the gauge indicates 10 in. Hg of vacuum on the radio.Observe the
gauge for approximately 2 minutes.
• If the needle falls 0.5 in. Hg or less (one scale interval, for example, from 10 in. Hg to 9.5 in.
Hg), then the radio has passed the vacuum test and is approved for immersibility. No
additional testing will be required.
• If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 10 in. Hg to less
than 9.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if
immersed. Additional troubleshooting of the radio will be required; complete this procedure,
then go to Section 5.8.8 "Pressure Test".
7. Remove the vacuum hose and pump connector from the radio.
5.8.8 Pressure Test
Pressure testing the radio is necessary only if the radio has failed the vacuum test. Do not perform
the pressure test until the vacuum test has been completed. Pressure testing involves creating a
positive pressure condition inside the radio, immersing the radio in water, and observing the radio
for a stream of bubbles (leak). Since all areas of the radio are being checked, observe the entire unit
carefully for the possibility of multiple leaks before completing this test.
To conduct the pressure test:
1. Screw the pump connector (with fitting seal) into the tapped hole in the chassis.
2. Attach one end of the pressure hose to the pump connector and the other end to the pressure
pump.
4. Operate the pump until the gauge reads approximately 1 psig.
! Pressure any greater than 1 psig might push air around the main seal
Caution
5. Maintain the pressure at 1 psig and immerse the radio into a water-filled container.
6. Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.
NOTE Some air entrapment may cause the accumulation of bubbles, especially in the grille area,
but the bubbles should not be continuous.
! Please do not bend or over tighten pump connector to the chassis.

Caution
7. Note all of the seal areas that show signs of leakage. Pinpoint the problem(s) to one (or more)
of the following areas:
• Front Housing
• Chassis kit
• Battery Contact Seal
8. Remove the radio from the water container, and dry the radio thoroughly. Be especially
careful to dry the area around the main seal to prevent contamination of the internal
electronics while the unit is open
! Keep the area around the chassis’s vacuum port dry by ensuring that there is no
water around it.
Caution
9. Remove the pump connector from the chassis.

10. Radio after performing Pressure Test must undergo baking process in a temperature chamber
for constant temperature soaking at 60°C for 1 hour. This is to ensure no moisture is trapped
inside the radio and prevent contamination of the internal electronics after reassembling the
radio.
5.8.9 Troubleshooting Leak Areas
Before repairing any leak, first read all of the steps within the applicable section. This will help to
eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot
only the faulty seal areas listed in Section 5.8.8 "Pressure Test" on page 5-32, and when multiple
leaks exist, in the order listed.
NOTE Before reassembling the radio, always install a Battery Contact Seal in the defective area.
5.8.9.1 Front Housing
Do one or both of the following:
1. If a leak occurs at the Lens (Display Models only), Universal Connector, chassis/Housing
interface, PTT button area of the housing, replace the housing. Refer to Section 5.6 "Radio
Disassembly – Detailed" on page 5-6.
a. Remove the housing assembly from the radio.
b. Discard the housing assembly.
c. Install a new housing assembly to the radio.
2. If the leak occurs at the control top area, remove the knobs in order to determine the leak
location:
a. Conduct the Pressure Test.
b. Identify the leak location.
5.8.9.2 Battery Contact Seal
To replace the Battery Contact Seal:
1. Refer to Section 5.6 "Radio Disassembly – Detailed" on page 5-6 to remove the Battery
Contact Seal.
2. Remove the Battery Contact Seal from the Chassis.
3. Inspect the Battery Contact Seal, Chassis and surrounding areas for foreign material that
might prevent the Battery Contact Seal from sealing properly.
4. Install a new Battery Contact Seal; discard the old Seal.
5. Reassemble the chassis assembly followed by installing into Front Cover. (Refer to Section
5.7 "Radio Reassembly - Detailed" on page 5-21).
IMPORTANT: Both Air Ventilation Label (54012316001) and Gasket (3286058L01)

need to be replaced after vacuum test, pressure test or water leakage
troubleshooting.
5.8.9.3 Air Ventilation Label
To replace the Air Ventilation Label:
1. Remove the Air Ventilation label from the chassis.

2. Ensure that the chassis’s surface (at the Air Ventilation label recess) is clean, no/minimum
scratches and free from any adhesive or other foreign materials.
3. Install a new Air Ventilation label, covering the vent port hole, in the small recessed area in
the chassis. Ensure that no oily substance come in contact with the seal.
4. Install a new Air Ventilation label in the larger recessed area in the chassis. Press down
evenly over the label’s surface to ensure good adhesion.
5.8.9.4 Battery Maintenance

1. As part of an Annual Battery Maintenece Program or as required (when the battery contacts
are dirty or show signs of wear) it is recommended that the Battery‘s Radio-side and Charger-
side contacts are cleaned with DeoxIT®GOLD cleaner/lubricant.
2. DeoxIT®GOLD (Supplier CAIG Labs, P/N G100P) cleaner/lubricant pen has been found to be
very effective at cleaning and extending the life of the battery‘s contacts. DeoxIT®GOLD
cleaner/lubricant is available at numerous electronics suppliers (Radio Shack, McMaster Carr,
Fry’s, etc.) and directly from manufacturer, CAIG Labs, at http://www.caig.com.
3. This pen based package is recommended as it provides better access to the recessed con-
tacts of the battery. The pen’s tip may need to be modified (trimmed on the sides) to improve
penetration into the battery contact slots. Per the manufacturer’s instructions, shake the pen
until the fluid begins to flow and wipe the battery's contact surface with the felt tip. After
cleaning, inspect the contact surfaces for signs of advanced wear.
4. Advanced contact wear is defined as wear through either the contact platings (gold and
nickel) to the base metal (copper). Copper exposure is characterized by a distinctive orange-
brown metal appearance surrounded by the silvery nickel underplate and gold top coat.
5. In some cases, a magnified (10x minimum) inspection may be required to verify wear through
to the base material. Polishing of the gold or nickel surface is common and is not considered
a need for replacement. In instances where advanced wear is evident, the battery should be
replaced.
6. After cleaning the contact areas of any foreign material, let the lubricant/cleaner dry for 2 min-
utes. Replace the battery on the radio and test for intermittency by moving the battery relative
to the radio as might occur in regular use.
NOTE Regular maintenance (at least annually) of this area is recommended to ensure
contamination free interface and to prolong the life of the battery contacts.
5.8.10 Troubleshooting Charts
Start
1. Remove Battery
2. Remove Universal
Connector Dustcover
3. Remove breathing vent label
and membrane
A
2. Attach vacuum hose to vacuum
pump
3. Ensure fitting seal is attached to
hose-to-chassis pump connector
4. Screw pump connector into
chassis’s tapped hole
5. Attach vacuum hose to pump
connector
6. Place radio on flat surface
7. Operate pump (gauge = 9 in. Hg)
Gauge Full
does not fall equipment for
NO YES
below pressure test Run Pressure Test
0.5 in. Hg procedure
available
YES
NO
1.Replace air
ventilation label
and gasket
B
2. Radio approved
for immersibility
End
Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)

End
Start
1Remove pump and Send radio to

connectors from radio Motorola Depot
2. Remove antenna or
3. Separate front housing kit Motorola Service Center
YES
Changed YES Changed

front housing chassis
kit kit
NO NO
Replace front Apply grease to the full

housing kit with perimeter of the chassis O-ring
new unit and replace the Chassis Kit
without PCBs

A
Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)

Start
1. Remove vacuum hose from

pump connector
2. Attach pressure hose to
pump connector
1. Operate pressure pump

(pressure = 1 psig)
2. Immerse radio into a water- 1. Remove Knobs
filled container
NO
Bubbles from 1. Dry the radio

Continuous YES Lens*/Univer- YES 2. Apply grease to the full
YES Bubbles from sal Connector/
Series of perimeter of the chassis O-Ring
Front chassis/
bubbles and replace Chassis Kit and
Housing Housing Inter- repeat steps in Troubleshooting
face/ PTT Flow Chart for Vacuum Test
NO NO * Only for Display Model
1. Dry the radio

2.Replace Air
Ventilation Label and
End Gasket
3. Radio approved
for immersibility
1. Dry the radio
YES 2. Apply grease to the full
Bubbles from perimeter of the chassis O-Ring
Chassis and replace Chassis Kit and
repeat steps in Troubleshooting
Flow Chart for Vacuum Test
NO
1. Dry the radio

NO Bubbles from YES 2. Replace Battery Contact Seal,
Battery Con- Apply grease to the full
tact Seal perimeter of the chassis O-Ring
and replace Chassis Kit. Repeat
steps in Troubleshooting Flow Chart
for Vacuum Test
Troubleshooting Flow Chart for Pressure Test & Leakage Areas

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists 5-39
5.9 Radio Exploded Mechanical Views and Parts Lists

5.9.1 Full Keypad Model Exploded View and Parts List
9.0
4.0
8.0
3.08
3.11
3.09
3.13
3.12
3.07
3.10
3.06
3.04
3.05
3.03
3.0
3.02
2.21
3.01
2.19
2.22
2.14
2.24
2.13
2.20
2.09
2.18
2.08
2.17
2.16
2.15
2.12
2.10
2.07
2.06
5.0
2.01
2.11
6.0
2.02
2.05
2.03
2.04
10.0
2.23
1.0
7.0
Figure 5-41. Full Keypad Model Exploded View

5-40 Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists
Table 5-3. Full Keypad Model Exploded View Parts List
Item Description Part Number
1 Antenna See Chapter 1.4: Model

Charts
2 Front Kit Assembly See Table 5-6. Additional

Part List Table
2.01 Front Housing Assembly See Table 5-6. Additional

Part List Table
2.02 Emergency Button 38012008001
2.03 UC Escutcheon 13012035001
2.04 Mic Membrane With Stiffener SL000209A01
2.05 Boot, Microphone SL000208A01
2.06 GPS/GLONASS Antenna See Table 5-6. Additional

Part List Table
2.07 Screw Shoulder, M1.2 X 3.2MM 0371160D01
2.08 Speaker Mesh SL000217A01
2.09 Speaker AC000028A02
2.10 UC Flex PF000917A01
2.11 Interface Flex PF000915A01
2.12 Keypad Flex See Table 5-6. Additional

Part List Table
2.13 Speaker Retainer- Grounding Contact Assembly 0104068J82
2.14 Screw, Thread Forming 0386434Z02
2.15 Front Dampener, Color Display 75012070001
2.16 Display Side Padding 75012137001
2.17 Display Module 72012010004
2.18 Back Dampener, Color Display HW000613A01
2.19 Microphone 50012012003
2.20 Keypad Controller (FKP) 0104065J47
2.21 Interface Board 0104065J48
2.22 Screw, Keypad Retainer 0378212A04
2.23 Front Nameplate 33012037001
2.24 Conductive Pad 75012224001
3 Back Cover Kit Assembly See Table 5-6. Additional

Part List Table
Table 5-3. Full Keypad Model Exploded View Parts List (Continued)
3.01 Screw, Main Board and GOB Board 03012034001
3.02 Option Board Kit See Table 5-6. Additional

Part List Table
3.03 GOB Flex 84012217003
3.04 Flex PF001167A01
3.05 Pad, Thermal 75012234001
3.06 Seal, Top Control 32012269001
3.07 Chassis, Kit 0104065J49
3.08 Shroud 15012092001
3.09 RF Rubber Plug 38012017001
3.10 Battery Contact Seal SL000213A01
3.11 Air Ventilation Label 54012316001
3.12 Gasket 3286058L01
3.13 TIA Label Service Non Field Replaceable
4 Nameplate See Table 5-6. Additional

Part List Table
5 Volume Knob 36012005001
6 Frequency Knob 36012004001
7 Dust Cover Assembly 15012157001
8 Battery See Table 5-6. Additional

Part List Table
9 Belt Clip See Table 5-6. Additional

Part List Table
10 Antenna ID See Table 5-6. Additional

Part List Table
5.9.2 Limited Keypad Model Exploded View and Parts List
9.0
4.0
8.0
3.08
3.09
3.13
3.11
3.10
3.07
3.12
3.06
3.04
3.05
3.03
3.02
3.0
3.01
2.21
2.22
2.19
2.18
2.14
2.20
2.24
2.13
2.17
2.09
2.16
2.15
2.08
2.10
2.12
2.06
2.11
2.01
5.0
2.07
2.02
2.05
6.0
2.04
2.03
1.0
10.0
2.23
7.0
Figure 5-42. Limited Keypad Model Exploded View

Table 5-4. Limited Keypad Model Exploded View Parts List

Charts
2 Front Kit Assembly See Table 5-6. Additional

Part List Table
2.01 Front Housing Assembly See Table 5-6. Additional

Part List Table
2.06 Beidou/GLONASS Antenna See Table 5-6. Additional

Part List Table
2.08 Speaker Mesh SL000217A01
2.10 UC Flex PF000917A01
2.12 Keypad Flex See Table 5-6. Additional

Part List Table
2.13 Speaker Retainer- Grounding Contact Assembly 0104068J82
2.15 Front Dampener, Color Display 75012070001
2.16 Display Side Padding 75012137001
2.17 Display Module 72012010004
2.18 Back Dampener, Color Display HW000613A01
2.19 Microphone 50012012003
2.20 Keypad Controller (LKP) 0104070J41
2.23 Front Nameplate 33012037001
3 Back Cover Kit Assembly See Table 5-6. Additional

Part List Table
Table 5-4. Limited Keypad Model Exploded View Parts List (Continued)
3.02 Option Board Kit See Table 5-6. Additional

Part List Table
3.03 GOB Flex 84012217003
3.04 Flex PF001167A01
3.05 Pad, Thermal 75012234001
3.07 Chassis, Kit 0104065J49
3.08 Shroud 15012092001
3.09 RF Rubber Plug 38012017001
3.12 Gasket 3286058L01
4 Nameplate See Table 5-6. Additional

Part List Table
8 Battery See Table 5-6. Additional

Part List Table
9 Belt Clip See Table 5-6. Additional

Part List Table
10 Antenna ID See Table 5-6. Additional

Part List Table
5.9.3 Non Keypad Model Exploded View and Parts List
9.0
4.0
3.09
8.0
3.13
3.08
3.11
3.10
3.12
3.07
3.06
3.04
3.03
3.05
3.0
3.02
3.01
2.15
2.19
2.16
2.14
2.13
2.18
2.12
2.09
2.10
2.11
2.08
2.07
5.0
2.01
2.05
2.06
2.04
1.0
6.0
2.02
2.03
10.0
2.17
7.0
Figure 5-43. Non Keypad Exploded View

Table 5-5. Non Keypad Model Exploded View Parts List

Charts
2 Front Kit Assembly See Table 5-6. Additional Part
List Table
2.01 Front Housing Assembly See Table 5-6. Additional Part
List Table
2.06 GPS/GLONASS Antenna See Table 5-6. Additional Part
List Table
2.08 Mesh, Speaker SL000217A01
2.10 UC Flex PF000917A01
2.12 Speaker Retainer- Grounding Contact 0104068J82
Assembly
2.14 Microphone 50012012003
2.17 Nameplate, Front 33012037001
2.18 Plain Front Housing Poron 75012131001
3 Back Cover Kit Assembly See Table 5-6. Additional Part
List Table
3.02 Option Board Kit See Table 5-6. Additional Part
List Table
3.03 GOB Flex 84012217003
3.04 Flex PF001167A01
3.05 Pad, Thermal 75012234001
Table 5-5. Non Keypad Model Exploded View Parts List (Continued)
3.07 Chassis, Kit 0104065J49

3.08 RF Rubber Plug 38012017001
3.09 Shroud 15012092001
3.12 Gasket 3286058L01
4 Nameplate See Table 5-6. Additional Part
List Table
8 Battery See Table 5-6. Additional Part
List Table
9 Belt Clip See Table 5-6. Additional Part
List Table
10 Antenna ID See Table 5-6. Additional Part
List Table
Table 5-6. Additional Part List Table

Front Kit - VHF
VHF Front Cover Kit, Roman Keypad, GNSS PMLN7360_
VHF Front Cover Kit, Roman Keypad PMLN7322_
VHF Front Cover Kit, Arabic Keypad, GNSS PMLN7385_
VHF Front Cover Kit, Arabic Keypad PMLN7386_
VHF Front Cover Kit, Cyrillic Keypad, GNSS PMLN7387_
VHF Front Cover Kit, Cyrillic Keypad PMLN7388_
VHF Front Cover Kit, Hebrew Keypad, GNSS PMHN4338_
VHF Front Cover Kit, Hebrew Keypad PMHN4339_
VHF Front Cover Kit, LKP, GNSS PMLN7419_
VHF Front Cover Kit, LKP PMLN7420_
VHF Front Cover Kit, NKP, GNSS PMLN7361_
VHF Front Cover Kit, NKP PMLN7323_
Front Kit -
UHF/300/350
MHz
UHF/300/350 MHz Front Cover Kit, Roman Keypad, PMLN7427_
GNSS
UHF/300/350 MHz Front Cover Kit, Roman Keypad PMLN7426_
UHF/300/350 MHz Front Cover Kit, Arabic Keypad, GNSS PMLN7430_
UHF/300/350 MHz Front Cover Kit, Arabic Keypad PMLN7431_
UHF/300/350 MHz Front Cover Kit, Cyrillic Keypad, GNSS PMLN7428_
UHF/300/350 MHz Front Cover Kit, Cyrillic Keypad PMLN7429_
UHF/300/350 MHz Front Cover Kit, Hebrew Keypad, PMHN4350_
GNSS
UHF/300/350 MHz Front Cover Kit, Hebrew Keypad PMHN4351_
UHF/300/350 MHz Front Cover Kit, LKP, GNSS PMLN7452_
UHF/300/350 MHz Front Cover Kit, LKP PMLN7453_
UHF/300/350 MHz Front Cover Kit, NKP, GNSS PMLN7361_
UHF/300/350 MHz Front Cover Kit, NKP PMLN7323_
Front Housing
Assembly
Front Housing Assembly FKP, English 0104065J42
Front Housing Assembly LKP 0104070J40
Front Housing Assembly FKP, Cyrillic 0104068J83
Front Housing Assembly FKP, Arabic 0104068J84
Front Housing Assembly FKP, Hebrew 0104068J89
Front Housing Assembly NKP 0104065J43
Back Kits*
VHF
BC Kit, 136–174 MHz, 5W, FKP with GNSS PMLD4727_S
Table 5-6. Additional Part List Table (Continued)

BC Kit, 136–174 MHz, 5W, FKP PMLD4776_S
BC Kit 136–174 MHz, 5W, FKP, Cyrillic, GNSS, BT, WiFi WAED4463_
BC Kit 136–174 MHz, 5W, FKP, Cyrillic WAED4464_
BC Kit 136–174 MHz, 5W, FKP, Arabic, GNSS, BT, WiFi WAED4465_
BC Kit 136–174 MHz, 5W, FKP, Arabic WAED4466_
BC Kit 136–174 MHz, 5W, FKP, Hebrew, GNSS, BT, WiFi WAED4467_
BC Kit 136–174 MHz, 5W, FKP, Hebrew WAED4468_
BC Kit, 136–174 MHz, 5W, MOTOTRBO LKP with GNSS PMLD4832_S
BC Kit, 136–174 MHz, 5W, MOTOTRBO LKP PMLD4834_S
BC Kit, 136–174 MHz, 5W, MOTOTRBO NKP with GNSS PMLD4729_S
BC Kit, 136–174 MHz, 5W, MOTOTRBO NKP PMLD4777_S
300/350 MHz
BC Kit, 300–360 MHz, 4W, FKP, GNSS, Bluetooth PMLD4794_S
BC Kit, 300–360 MHz, 4W, NKP, GNSS. Bluetooth PMLD4796_S
BC Kit, 350–400 MHz, 4W, FKP, GNSS, BT, WiFi PMLD4753_S
BC Kit, 350–400 MHz, 4W, NKP, GNSS, BT, WiFi PMLD4754_S
BC Kit, 350–400 MHz, 4W, FKP PMLD4756_S
BC Kit, 350–400 MHz, 4W, NKP PMLD4757_S
UHF
BC Kit, 403–527 MHz, 4W, MOTOTRBO FKP with GNSS PMLE5064_S
BC Kit, 403–527 MHz, 4W, MOTOTRBO FKP PMLE5088_S
BC Kit, 403–527 MHz, 4W, FKP, Cyrillic, GNSS, BT, WiFi WAEE4502_
BC Kit, 403–527 MHz, 4W, FKP, Cyrillic WAEE4503_
BC Kit, 403–527 MHz, 4W, FKP, Arabic, GNSS, BT, WiFi WAEE4504_
BC Kit, 403–527 MHz, 4W, FKP, Arabic WAEE4505_
BC Kit, 403–527 MHz, 4W, FKP, Hebrew, GNSS, BT, WiFi WAEE4506_
BC Kit, 403–527 MHz, 4W, FKP, Hebrew WAEE4507_
BC Kit, 403–527 MHz, 4W, LKP with GNSS PMLE5148_S
BC Kit, 403–527 MHz, 4W, LKP PMLE5150_S
BC Kit, 403–527 MHz, 4W, MOTOTRBO NKP with GNSS PMLE5066_S
BC Kit, 403–527 MHz, 4W, MOTOTRBO NKP PMLE5090_S
Option Board
Kit
Generic Option Board Kit PMLN7324_S
MPT Option Board Kit PMLN7394_S
Connect Plus Option Board Kit PMLN7395_S
Keypad Flex
Assy Flex, Mainboard to Keypad Board (VHF & 8/900 0104065J46
MHz)
PCBA Flex Assembly, 3 Layer (UHF, 300 MHz & 350 MHz) PA001338A01
Nameplate
Table 5-6. Additional Part List Table (Continued)

DP4400e Nameplate 33012015052
Antenna ID
Band
Antenna ID band (Grey-10pcs) 32012244001
Antenna ID band (Yellow-10pcs) 32012244002
Antenna ID band (Green-10pcs) 32012244003
Antenna ID band (Blue-10pcs) 32012244004
Antenna ID band (Purple-10pcs) 32012244005
Battery
IMPRES Li-Ion TIA4950 HAZLOC IP68 2900T LV PMNN4489_
Standard NiMH 1300 mAh IP67 1400T PMNN4412_
IMPRES Li-Ion Slim 1500 mAh PMNN4407_
IMPRES Hi-Cap Li-Ion Non-FM 2150 mAh PMNN4409_
Core Slim Li-Ion 1500 mAh PMNN4406_
IMPRES FM Li-Ion 2300 mAh 2350T NNTN8129_
IMPRES Li-Ion 2300 mAh 2350T PMNN4424_R**
IMPRES IP67 Li-Ion 2700 mAh 2800T PMNN4448_R
Li-Ion IP57 2000 mAh PMNN4463_
Li-Mn 1400 mAh low temp -30C battery Submersible PMNN4435_R
(IP57)
IMPRES Slim Li-Ion IP68 2100T PMNN4491_
IMPRES Li-Ion IP68 3000T LV PMNN4493_
IMPRES Li-Ion VIB IP68 3000T LV PMNN4488_
Belt Clips
Belt Clip 2” PMLN4651_
Belt Clip 2.5" PMLN7008_
Vibrating Belt Clip 2.5” PMLN7296_
GNSS Antenna
Antenna, Chip, GLONASS BT/GPS Antenna Module AN000151A01
* For defective main boards, customers must order Back Kit.
** For 300/350 MHz only
5.9.4 Torque Chart

Table 5-7 lists the various screws by part number and description, followed by the torque values in
different units of measure. Torque all screws to the recommended value when assembling the radio.
Table 5-7. Torque Specifications for Screws
Driver/ Torque
Part Number Description
Socket lbs-in N-m
03012034001 Screw, Main Board (new chassis) 6 IP Torx Plus 3.1 to 3.3 0.35 to 0.37
Screw, Main Board (rework) 6 IP Torx Plus 2.0 0.22
0386434Z02 Screw, Thread Forming 6 IP Torx Plus 3.5 to 4.3 0.40 to 0.49
0378212A04 Screw, Keypad Retainer 6 IP Torx Plus 1.8 to 2.2 0.20 - 0.25
0371160D01 Screw, Shoulder, M1.2 X 3.2 MM T4 Torx 0.4 to 0.6 0.04 - 0.06
Notes
Chapter 6 Basic Troubleshooting
6.1 Introduction
This chapter contains error codes and board replacement procedures. If the board does not pass all
the performance checks in Chapter 3 or exhibits an error code listed below, then the circuit board
should be replaced. If repair requires knowledge of details of component level troubleshooting,
please send radio to a Motorola Service Center listed in Appendix A.
NOTE To access the various connector pins, use the housing eliminator/test fixture along with the
diagrams found in this section of the manual. (See the section, "Service Aids" on page 2-2,
for the appropriate Motorola service aids and tools parts numbers.)
6.2 Replacement Back Cover Kit Procedures

Once a problem has been isolated to a specific board, install the appropriate service kit (See Model
Charts in Chapter 1), which is orderable.
If a board is replaced, it does not necessarily need to be retuned if it has been factory tuned. It
should however be checked for performance before being placed into service. Of particular concern
is the Bias DAC, which will need to be set for the appropriate final device bias current prior to keying
up the radio. If the bias is not properly set it may be possible to cause damage to the transmitter.
! The Tuner Tool only allows the serial number of the blank board to be entered
once. Be very attentive during this procedure.
Caution
6-2 Basic Troubleshooting Power-Up Error Codes (Display Model only)
6.3 Power-Up Error Codes (Display Model only)

Upon powering up, the radio performs certain tests to determine if its basic electronics and software
are in working order. Any error detected has an associated error code that is presented on the radio
display. These error codes are intended to be used by a service technician when the radio
generates the Self Test Fail Tone. If these tests are successfully completed, the radio will generate
the Self Test Tone.
There are two classes of detectable errors, fatal and non-fatal. If it is considered as a fatal error, then
the normal radio operation will be inhibited. Fatal errors include hardware errors detected by the
microprocessor and certain memory errors. These memory errors include incorrect ROM checksum,
incorrect RAM checksum, and incorrect checksums of codeplug (Persistent Storage) blocks that
contain operating parameters. If the codeplug block operating parameters are corrupted, operation
of the unit on the proper frequency, system, and group are in question. Attempts to use this
information could provide the user with a false sense of security that others are receiving his
messages. Corrupted codeplug blocks of call IDs, or their associated aliases are considered non-
fatal errors. While the user may be inconvenienced, normal communication is still possible.
Table 6-1. Power-Up Error Codes
Error Code Description Error Type Corrective Action

ERROR 01/02 Call ID or associated Non-Fatal Normal communication is still possible, but the
aliases codeplug block user may be inconvenienced.
checksum is wrong. Reprogram codeplug.
ERROR 01/22 Tuning Codeplug block Non-Fatal Normal communication is still possible.
checksum is wrong.
FAIL 01/82 External Codeplug block Fatal Reprogram codeplug.
checksum is wrong.
FAIL 01/92 Secure Codeplug check- Fatal Reprogram codeplug.
sum error
FAIL 01/A2 Tuning Codeplug block Fatal Reprogram codeplug.
checksum is wrong.
FAIL 01/81 ROM Checksum is Fatal Reprogram FLASH Memory, then retest. If
wrong. message reoccurs, replace main board or
send radio to nearest Motorola Depot.
FAIL 01/88 Radio RAM Test Failure. Fatal Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.
FAIL 01/90 General hardware test Fatal Retest radio by turning it off and turning it on
or failure. again. If message reoccurs, replace main
FAIL 02/90 board or send radio to nearest Motorola
Depot.
FAIL 02/81 DSP ROM Checksum is Fatal Reprogram FLASH Memory, then retest. If
wrong. message reoccurs, replace main board or
send radio to nearest Motorola Depot.
FAIL 02/82 DSP RAM1 test failure. Fatal Retest radio by turning it off and turning it on
Depot.
Basic Troubleshooting Power-Up Error Codes (Display Model only) 6-3
Table 6-1. Power-Up Error Codes (Continued)

FAIL 02/84 DSP RAM2 test failure. Fatal Retest radio by turning it off and turning it on
Depot.
FAIL 02/88 DSP RAM test failure. Fatal Retest radio by turning it off and turning it on
Depot.
FAIL 02/C0 DSP ROM Checksum is Fatal Retest radio by turning it off and turning it on
wrong. again. If message reoccurs, replace main
Depot.
No Display Display module is not Fatal Check connection between main board and
connected properly. display module.
Display module is dam- Replace with new display module.
aged.
6-4 Basic Troubleshooting Operational Error Codes
6.4 Operational Error Codes

During radio operation, the radio performs dynamic tests to determine if the radio is working properly.
Problems detected during these tests are presented as error codes on the radio’s display. The
presence of an error code should prompt a user that a problem exists and that a Motorola Authorized
MOTOTRBO dealer should be contacted. Use Table 6-2 to aid in understanding particular
operational error codes.
Table 6-2. Operational Error Codes

FAIL 001 Synthesizer Out-of-Lock NON-FATAL 1. Reprogram the codeplug.
2. Refer to Detailed Service
Manual.
FAIL 002 Personality checksum or NON-FATAL Reprogram the codeplug.
system block error
Appendix A EMEA Regional Warranty, Service and
Technical Support
A.1 Warranty and Service Support

Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warranty period, and service/ repair or spare parts support out of warranty.
Any "return for exchange" or "return for repair" by an authorized Motorola Dealer must be
accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an
Authorized Motorola Dealer.
A.1.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only.
In instances where the product is covered under a "return for replacement" or "return for repair"
warranty, a check of the product should be performed prior to shipping the unit back to Motorola.
This is to ensure that the product has been correctly programmed or has not been subjected to
damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources (Please see page A-3). All returns must be accompanied by a Warranty Claim
Form, available from your Customer Services representative. Products should be shipped back in
the original packaging, or correctly packaged to ensure no damage occurs in transit.
A.1.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola's Managed Technical Services (MTS) offers a repair service to both end users and
dealers at competitive prices.
2. MTS supplies individual parts and modules that can be purchased by dealers who are
technically capable of performing fault analysis and repair.
A-2 EMEA Regional Warranty, Service and Technical Support: European Radio Support Centre (ERSC)
A.2 European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:
Austria: 08 00 29 75 41 Italy: 80 08 77 387
Belgium: 08 00 72 471 Luxemburg: 08 00 23 27
Denmark: 80 88 58 80 Netherlands: 08 00 22 45 13
Finland: 08 00 11 49 910 Norway: 80 01 11 15
France: 08 00 90 30 90 Portugal: 08 00 84 95 70
Germany: 08 00 18 75 240 Spain: 90 09 84 902
Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307
UK : 08 00 96 90 95 Switzerland: 08 00 55 30 82
Ireland: 18 00 55 50 21 Iceland: 80 08 147
Or dial the European Repair and Service Centre:

Telephone: +49 30 6686 1555
Fax ERSC: +49 30 6686 1579
Email ERSC: ERSC@motorolasolutions.com
Please use these numbers for repair enquiries only.
A.3 Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly.
If a complete Motorola part number is assigned to the part, it is available from Motorola Radio
Products and Solutions Organization (RPSO). If no part number is assigned, the part is not normally
available from Motorola. If the part number is appended with an asterisk, the part is serviceable by
Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable parts
are available for that kit or assembly.
Orders for replacement parts, kits and assemblies should be placed directly on Motorola's local
distribution/dealer organisation or via Motorola Online at: http://www.motorola.com/emeaonline
* The Radio Products and Solutions Organization (RPSO) was formerly known as the Radio
Products Services Division (RPSD) and/or the Accessories and Aftermarket Division (AAD).
EMEA Regional Warranty, Service and Technical Support: Technical Support A-3
A.4 Technical Support

Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions
which may be encountered.
Central and East Europe – Siggy Punzenberger

Telephone: +49 (0) 6128 70 2342
Fax: +49 (0) 6128 95 1096
Email: TFG003@motorolasolutions.com
Russia and Armenia – Andrey Nagornykh Germany – Customer Connect Team

Telephone: +7 495 787 8910 Telephone: +49 (0) 30 6686 1539
Fax: +7 495 785 0185 Fax: +49 (0) 30 6686 1916
Email: mwcb47@motorolasolutions.com Email: ESSC@motorolasolutions.com
Middle East and Africa – Wayne Holmes Italy – Ugo Gentile

Telephone: +49 (0) 6126 957 6237 Telephone: +39 02 5220 7825
Fax: +49 (0) 6126 957 6826 Fax: +39 02 5220 7810
Email: wayne.holmes@motorolasolutions.com Email: Ugo.Gentile@motorolasolutions.com
France – Armand Roy France – Laurent Irrmann

Telephone: +33 1 6935 7868 Telephone: +33 1 6935 7866
Fax: +33 1 6935 7808 Fax: +33 1 6935 7808
Email: armand.roy@motorolasolutions.com Email: laurent.irrmann@motorolasolutions.com
A.5 Further Assistance From Motorola

You can also contact the Customer Help Desk through the following web address.
http://www.motorolasolutions.com/
A-4 EMEA Regional Warranty, Service and Technical Support: Further Assistance From Motorola
Notes
Appendix B Limited Level 3 Servicing
B.1 Maintenance
For details on the following, please refer to “Chapter 5 Disassembly/Reassembly Procedures” on
page 5-1 to section 5.4 on page 5-4.
Section 5.2 on page 5-1 to Section 5.4 on page 5-4.
• Preventive maintenance (inspection and cleaning).
• Safe handling of CMOS and LDMOS devices.
• Repair procedures and techniques.
B.2 Chip Components

Use a Hot-Air Repair Station for chip component replacement. Adjust the temperature control to
370°C (700°F), and adjust the airflow to a minimum setting. Airflow can vary due to component
density.
• To remove a chip component:
1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm
(1/8") above the component to be removed.
2. Begin applying the hot air. Once the solder reflows, remove the component using a pair
of tweezers.
3. Using a solder wick and a soldering iron or a power desoldering station, remove the
excess solder from the pads.
• To replace a chip component using a soldering iron:
1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the
solder pads.
2. Using a pair of tweezers, position the new chip component in place while heating the
fresh solder.
3. Once solder wicks onto the new component, remove the heat from the solder.
4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the
component. If necessary, touch up the first side. All solder joints should be smooth and
shiny.
• To replace a chip component using hot air:
1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.
2. Apply a drop of solder paste flux to each pad.
3. Using a pair of tweezers, position the new component in place.
4. Position the hot-air hand piece approximately 0.3 cm (1/8") above the component and
begin applying heat.
5. Once the solder wicks to the component, remove the heat and inspect the repair. All
joints should be smooth and shiny.
B-2 Limited Level 3 Servicing: Component and Parts list
B.3 Component and Parts list
4
SW4044
5
3
2
Figure B-1. PCB Top View

S4030
S4010
3 4
7
2
6
14 13
E0800
2 4
3
2
3 2
3 M0800 4
5 4
3
12 10
6
5
F4020
M4020
2 3
Figure B-2. PCB Bottom View

Limited Level 3 Servicing: Component and Parts list B-3
Table B-1 Component Parts List
No. Circuit Ref Motorola Part Num. Description
1 SW4044 4086470Z01 SPST Tact Switch
2 M0800 0987378K01 SM Coaxial Connector

E0800 CN000794A01 Female
3 S4010 40012023001 Frequency Switch
4 S4030 1875103C04 Volume Rotary On/Off

Switch
5 M4020 09012098002 Battery Contact

Connector
6 F4020 6515076H01 Fuse Fast Blow 3A 24V

B-4 Limited Level 3 Servicing: Component and Parts list
Notes
Glossary Glossary
Term Definition
Analog Refers to a continuously variable signal or a circuit or device designed

to handle such signals.
Band Frequencies allowed for a specific purpose.
BC Kit Back Cover Kit
BT Bluetooth
CPS Customer Programming Software: Software with a graphical user
interface containing the feature set of a radio.
Default A pre-defined set of parameters.
DP Refers to Digital Professional Radio model names in the MOTOTRBO
Professional Digital Two-Way Radio System.
Digital Refers to data that is stored or transmitted as a sequence of discrete
symbols from a finite set; most commonly this means binary data
represented using electronic or electromagnetic signals.
DPL Digital Private-Line: A type of digital communications that utilizes
privacy call, as well as memory channel and busy channel lock out to
enhance communication efficiency.
FCC Federal Communications Commission.
FKP Full Keypad Model
Frequency Number of times a complete electromagnetic-wave cycle occurs in a
fixed unit of time (usually one second).
GLONASS Global Navigation Satellite System
GPIO General-Purpose Input/Output: Pins whose function is programmable.
GPS Global Positioning System.
IC Integrated Circuit: An assembly of interconnected components on a
small semiconductor chip, usually made of silicon. One chip can contain
millions of microscopic components and perform many functions.
IF Intermediate Frequency.
kHz kilohertz: One thousand cycles per second. Used especially as a radio-
frequency unit.
Glossary-2
Term Definition
LCD Liquid-Crystal Display: An LCD uses two sheets of polarizing material

with a liquid-crystal solution between them. An electric current passed
through the liquid causes the crystals to align so that light cannot pass
through them.
LED Light Emitting Diode: An electronic device that lights up when electricity
is passed through it.
MDC Motorola Digital Communications.
MHz Megahertz: One million cycles per second. Used especially as a radio-
frequency unit.
MOR Ministry of Railway
MPT Ministry of Posts and Telecommunication.
NKP Non Keypad Model
Paging One-way communication that alerts the receiver to retrieve a message.
PC Board Printed Circuit Board. Also referred to as a PCB.
PL Private-Line Tone Squelch: A continuous sub-audible tone that is
transmitted along with the carrier.
Programming Cable A cable that allows the CPS to communicate directly with the radio
using USB.
Receiver Electronic device that amplifies RF signals. A receiver separates the
audio signal from the RF carrier, amplifies it, and converts it back to the
original sound waves.
Repeater Remote transmit/receive facility that re-transmits received signals in
order to improve communications range and coverage (conventional
operation).
RF Radio Frequency: The portion of the electromagnetic spectrum between
audio sound and infrared light (approximately 10 kHz to 10 GHz).
RX Receive.
Signal An electrically transmitted electromagnetic wave.
Spectrum Frequency range within which radiation has specific characteristics.
Squelch Muting of audio circuits when received signal levels fall below a pre-
determined value. With carrier squelch, all channel activity that exceeds
the radio’s preset squelch level can be heard.
TIA Telecommunications Industry Association
TOT Time-out Timer: A timer that limits the length of a transmission.
TPL Tone Private Line.
Glossary-3
Notes
Term Definition
Transceiver Transmitter-receiver. A device that both transmits and receives analog

or digital signals. Also abbreviated as XCVR.
Transmitter Electronic equipment that generates and amplifies an RF carrier signal,
modulates the signal, and then radiates it into space.
TX Transmit.
UHF Ultra-High Frequency.
USB Universal Serial Bus: An external bus standard that supports data
transfer rates of 12 Mbps.
VIP Vehicle Interface Port.
Glossary-4
Notes
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and
the Stylized M logo are trademarks or registered trademarks
of Motorola Trademark Holdings, LLC and are used under license.
All other trademarks are the property of their respective owners.
© 2016 Motorola Solutions, Inc. All rights reserved.
January 2016.
www.motorolasolutions.com/mototrbo
*MN002181A01*
MN002181A01-AA

DP 4000e Series BSM

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DP 4000e Series BSM

Uploaded by

Copyright:

Available Formats

PROFESSIONAL DIGITAL TWO-WAY RADIO SYSTEM

Product Safety and RF Exposure Compliance

Repairs of Motorola TIA 4950 certified intrinsically safe radios must

Computer Software Copyrights

Edition Description Date

MN002181A01-AA Initial Release Jan. 2016

Document History ......................................................................................... v

Chapter 1 Introduction ......................................................................... 1-1

Chapter 2 Test Equipment and Service Aids ..................................... 2-1

Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.3.10 Audio Loopback Earpiece Test Mode............................................................................ 3-10

Chapter 4 Radio Programming and Tuning ....................................... 4-1

Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1

5.8.9 Troubleshooting Leak Areas.......................................................................................... 5-33

Chapter 6 Basic Troubleshooting ....................................................... 6-1

Appendix A EMEA Regional Warranty, Service and Technical Support ..

Appendix B Limited Level 3 Servicing ...................................................B-1

Glossary ......................................................................................... Glossary-1

Figure 1-1. Full Keypad Model................................................................................................................ 1-2

Figure 5-37. Main board and GOB reassembly...................................................................................... 5-28

1.1 Notations Used in This Manual

NOTE An operational procedure, practice, or condition that is essential to emphasize.

! CAUTION indicates a potentially hazardous situation which, if

WARNING indicates a potentially hazardous situation

1.2 Radio Description

Table 1-1. Radio Frequency Ranges and Power Levels

Frequency Band Bandwidth Power Level

VHF 136–174 MHz 1 Watt or 5 Watt

UHF 403–527 MHz 1 Watt or 4 Watt

300 MHz Band 300–360 MHz 1 Watt or 4 Watt

350 MHz Band 350–400 MHz 1 Watt or 4 Watt

1.2.1 Full Keypad Model

Channel Selector Knob

Figure 1-1. Full Keypad Model

1.2.2 Limited Keypad Model

Channel Selector Knob

Side Button 2 LCD

Figure 1-2. Limited Keypad Model

1.2.3 Non Keypad Model

Channel Selector Knob

PTT Button Universal Connector

Figure 1-3. Non Keypad Model

1.3 .Portable Radio Model Numbering Scheme

Figure 1-4. Portable Radio Model Numbering Scheme

1.4 Model Charts

DP4000e Series, VHF, 136–174 MHz

DP4000e Series, VHF, 136–174 MHz (Continued)

1.4.2 UHF Model Chart

DP4000e Series, UHF, 403–527 MHz

1.4.3 300 MHz Band Model Chart

DP4000e Series, 300 MHz Band, 300–360 MHz

1.4.4 350 MHz Band Model Chart

DP4000e Series, 350 MHz Band, 350–400 MHz

Channel Capacity 1000 1000 32

Frequency VHF: 136 – 174 MHz

Weight (w/ PMNN4493_ IMPRES Low Volt

Power Supply 7.5V nominal

TIA 4950 UL Approval

NOTE Weight can have 5% margin of error

Receiver Full Keypad Limited Keypad Non Keypad

Frequencies VHF: 136 – 174 MHz

Channel Spacing 12.5 kHz/ 20 kHz*/ 25 kHz

Frequency Stability (-30°C to +/-0.5 ppm

Adjacent Channel Selectivity